Note: Descriptions are shown in the official language in which they were submitted.
DOWNHOLE VALVE ASSEMBLY WITH CEMENT-ISOLATED FLOWPATH
TECHNICAL FIELD
[001] The present disclosure relates to technologies for subterranean
operations and, more
particularly, to downhole valve assemblies, systems and methods that can be
used to inject
or produce fluids, and which can be implemented in cemented wellbore
completions.
BACKGROUND
[002] Recovering hydrocarbons from an underground formation can be enhanced by
fracturing the formation in order to form fractures through which hydrocarbons
can flow from
the reservoir into a well. Fracturing can be performed prior to primary
recovery where
hydrocarbons are produced to the surface without imparting energy into the
reservoir.
Fracturing can be performed in stages along the well to provide a series of
fractured zones in
the reservoir.
[003] Well completion often includes cementing the wellbore string down the
wellbore prior
to fractures being formed therein. The frac ports are initially closed during
the cementing
process, and are open to enable the fracturing of the formation. Valve
assemblies can then
be provided with various devices and apparatuses to enable the production of
reservoir fluids.
Due to some of the functionalities of these devices and apparatuses, they are
often run
downhole on a work string after having cemented the wellbore and fractured the
reservoir in
order to prevent damaging the devices. Running down work strings to reach
valve assemblies
dispersed along the wellbore string can be time-consuming and includes
inherent costs. There
is thus a general need for improvements in providing systems and devices down
a wellbore.
SUMMARY
[004] According to an aspect, a valve assembly for integration within a
wellbore string
disposed along a wellbore defined within a subterranean reservoir is provided.
The valve
assembly includes a valve housing comprising a top sub, a bottom sub and an
outer wall
extending between the top and bottom subs, the outer wall defining a central
passage
therethrough and having a housing port extending through the outer wall for
establishing fluid
communication between the central passage and the reservoir. The valve
assembly also has
a bottom sleeve operatively mounted within the valve housing and slidable
within the central
passage between a closed position where the bottom sleeve occludes the housing
port, and
an open position where the bottom sleeve is spaced from the housing port to
establish fluid
communication between the reservoir and the wellbore string through the
housing port. The
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Date Recue/Date Received 2022-09-28
valve assembly further includes a top sleeve operatively mounted within the
valve housing
between the bottom sleeve and the top sub, the top sleeve and the valve
housing defining an
annular region therebetween with the top sleeve being provided with a sleeve
port and being
slidable within the valve housing between (i) a first position where the
sleeve port is occluded
by the outer wall of the valve housing and where a restricted flowpath is
defined between the
outer wall and the top sleeve at an uphole end thereof to enable an ingress of
wellbore fluid
into the annular region, and (ii) a second position where the sleeve port
communicates with
the housing port to define a fluid pathway along which reservoir fluids are
flowable from the
reservoir, through the housing port and the sleeve port, into the annular
region, along the
annular region toward the uphole end of the top sleeve and into the central
passage of the
valve housing; and a flow control device coupled to the top sleeve and
operable to control a
flow of fluids along the fluid pathway when the top sleeve is in the
production position. When
in the first position, the top sleeve is in sealing engagement with the valve
housing for defining
a dead-end chamber within the annular region, the dead-end chamber being in
fluid
communication with the central passage via the restricted flowpath to enable
fluid
pressurization of the dead-end chamber and prevent cementitious material from
flowing into
the annular region, the flow control device being positioned within the dead-
end chamber and
being isolated from the cementitious material when the top sleeve is in the
first position.
[005] According to a possible implementation, the flow control device includes
a directional
control valve device adapted to prevent fluid flow in at least one direction
between the central
passage and the reservoir, when the top sleeve is in the second position.
[006] According to a possible implementation, the directional control valve
device is adapted
to prevent fluid flow from the central passage to the sleeve port via the
annular region, and
allow fluid flow from the sleeve port to the central passage via the annular
region.
[007] According to a possible implementation, the top sleeve comprises a
sleeve mandrel
defining a sleeve passage therethrough, a collet coupled to an uphole end of
the sleeve
mandrel and being adapted to releasably engage an inner surface of the outer
wall, and a
sleeve cap coupled to a downhole end of the sleeve mandrel, the sleeve cap
being provided
with the sleeve port, where at least one of the sleeve mandrel and the sleeve
cap sealingly
engages the outer wall to define the dead-end chamber.
[008] According to a possible implementation, the top sleeve comprises a
latching
mechanism configured to releasably connect the top sleeve to the outer wall
when the top
sleeve is in the first position and/or the second position.
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[009] According to a possible implementation, the outer wall comprises inner
annular
grooves and the latching mechanism comprises one or more protrusions adapted
to releasably
engage at least one of the annular grooves when the top sleeve is in the first
position and/or
the second position.
[010] According to a possible implementation, when the top sleeve is in the
first position, the
collet is adapted to engage the top sub and the outer wall, and wherein the
restricted flowpath
is defined between the top sub, the outer wall and the collet.
[011] According to a possible implementation, the sleeve mandrel comprises a
ring portion
extending into the annular region and engaging the inner surface of the outer
wall, the ring
portion defining a downhole annular region in fluid communication with the
sleeve port, and
an uphole annular region in fluid communication with the central passage, the
ring portion
comprises one or more through channels establishing fluid communication
between the
uphole and downhole annular regions.
[012] According to a possible implementation, the one or more through channels
comprise
a plurality of through channels provided at regular intervals around the
sleeve mandrel.
[013] According to a possible implementation, the directional control valve
device comprises
a displaceable member provided within the uphole annular region and being
movable between
an engaged position, where the displaceable member at least partially prevents
fluid
communication between the uphole and downhole annular regions, and a
disengaged
position, where fluid communication between the uphole and downhole annular
regions is
allowed, the directional control valve device further comprises a biasing
member operatively
coupled to the displaceable member for biasing the displaceable member in the
engaged
position.
[014] According to a possible implementation, the displaceable member is
movable from the
engaged position to the disengaged position via fluid flow from the reservoir
into the downhole
annular region and the through channels.
[015] According to a possible implementation, the directional control valve
device comprises
an axial check valve device, and wherein the displaceable member comprises a
ring plug
member slidably mounted about the sleeve mandrel, and the biasing member
comprises a
spring provided about the sleeve mandrel and operatively coupled between the
ring plug
member and the collet to bias the ring plug member in the engaged position.
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[016] According to a possible implementation, the ring plug member comprises a
front edge
adapted obstruct the through channels to at least partially prevent fluid
communication
between the uphole and downhole annular regions when in the engaged position,
and wherein
fluid flow from the reservoir into the through channels pushes on the front
edge and slides the
ring plug member in the disengaged position.
[017] According to a possible implementation, the ring portion comprises an
overhang
extending into the uphole annular chamber, and wherein the front edge is
tapered and adapted
to sealingly engage the overhang when in the engaged position.
[018] According to a possible implementation, the front edge of the ring plug
member is
circumferentially continuous.
[019] According to a possible implementation, the directional control valve
device comprises
a radial check valve device, and wherein the displaceable member comprises a
plurality of
radial poppets provided about the ring portion for obstructing respective
through channels
when in the engaged position.
[020] According to a possible implementation, the flow control device
comprises a screen
superposed with the sleeve port to allow fluid flow from the reservoir into
the annular region,
and prevent various particulates from entering the top sleeve and/or the
central passage.
[021] According to a possible implementation, the sleeve port comprises a
plurality of
elongate slots provided around the sleeve cap and opening on an outer surface
of the sleeve
cap, and wherein the screen comprises one or more circumferential openings
defined along
an interior surface of the sleeve cap and in fluid communication with the
elongate openings
through a bottom surface thereof.
[022] According to a possible implementation, the circumferential openings are
generally
perpendicular relative to the elongate slots.
[023] According to another aspect, a valve assembly for integration within a
wellbore string
disposed along a wellbore defined within a subterranean reservoir is provided.
The valve
assembly includes a valve housing comprising a top sub, a bottom sub and an
outer wall
extending between the top and bottom subs, the outer wall defining a central
passage
therethrough and having a housing port extending through the outer wall for
establishing fluid
communication between the wellbore string and the reservoir; a bottom sleeve
operatively
mounted within the valve housing and slidable within the central passage
between a closed
position where the bottom sleeve occludes the housing port, and an open
position where the
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bottom sleeve is spaced from the housing port to establish fluid communication
between the
reservoir and the wellbore string through the housing port; a top sleeve
operatively mounted
within the valve housing between the bottom sleeve and the top sub, the top
sleeve and the
valve housing defining an annular region therebetween, the top sleeve being
provided with a
sleeve port and being slidable within the central passage between (i) a first
position where the
sleeve port is occluded by the outer wall of the valve housing and where a
restricted flowpath
is defined between the outer wall and the top sleeve at an uphole end thereof
to enable an
ingress of fluid into the annular region, and (ii) a production position where
the sleeve port
communicates with the housing port to define a fluid pathway along which
fluids are flowable
from the reservoir, through the housing port and the sleeve port, into the
annular region, along
the annular region toward the uphole end of the top sleeve and into the
central passage of the
valve housing; and one or more seals provided between the top sleeve and the
outer wall for
sealing a downhole end of the annular region and defining a dead-end chamber
along the
annular region when the top sleeve is in the first position, where the ingress
of fluid into the
annular region via the restricted flowpath pressurizes the dead-end chamber to
prevent
cementitious material from flowing into the annular region during completion
of the wellbore.
[024] According to a possible implementation, the valve assembly further
includes a flow
control device coupled to the top sleeve and operable to control a flow of
fluids along the fluid
pathway when the top sleeve is in the production position, and where the flow
control device
is provided within the dead-end chamber and isolated from the cementitious
material when
the top sleeve is in the first position.
[025] According to another aspect, a valve assembly for integration within a
wellbore string
disposed along a wellbore defined within a subterranean reservoir is provided.
The valve
assembly includes a valve housing having an outer wall defining a central
passage
therethrough and having a housing port extending through the outer wall; a
bottom sleeve
operatively mounted within the valve housing and slidable within the central
passage between
a closed position occluding the housing port, and an open position; a top
sleeve operatively
mounted within the valve housing and defining an annular region therebetween,
the top sleeve
having a sleeve port and being slidable within the central passage between (i)
a first position
where a downhole end of the top sleeve sealingly engages an inner surface of
the valve
housing and defines an annular chamber within the annular region, and (ii) an
operational
position where the sleeve port is in fluid communication with the housing port
to define a fluid
pathway along which fluids are flowable from the reservoir through the annular
chamber and
into the central passage; and a flow control device provided within the
annular region and
being operable to control a flow of fluids along the fluid pathway when the
top sleeve is in the
Date Recue/Date Received 2022-09-28
operational position. The annular chamber is in fluid communication with the
central passage
for allowing wellbore fluid to flow into and pressurize the annular chamber to
prevent
subsequent fluid, particulates and/or slurry material from flowing into the
annular chamber,
and where the sleeve port and flow control device are positioned within the
annular chamber
when in the first position.
[026] According to a possible implementation, the subsequent fluid,
particulates and/or slurry
material comprises cement.
[027] According to a possible implementation, the wellbore fluid comprises
brine, water,
drilling mud or a combination thereof.
[028] According to another aspect, a valve assembly for integration within a
wellbore string
disposed along a wellbore defined within a subterranean reservoir is provided.
The valve
assembly includes a valve housing having an outer wall defining a central
passage
therethrough and having a housing port extending through the outer wall; a
valve sleeve
operatively mounted within the valve housing and defining an annular region
therebetween,
the valve sleeve having a sleeve port and being slidable within the valve
housing between (i)
a closed position where a downhole end of the valve sleeve occludes the
housing port to
prevent fluid communication between the reservoir and the central passage, and
(ii) an
operational position where the sleeve port is in fluid communication with the
housing port to
define a fluid pathway along which fluids are flowable from the reservoir
through the annular
region and into the central passage, when in the closed position, the downhole
end of the
valve sleeve sealingly engages an inner surface of the outer wall and defines
an annular
chamber within the annular region, the annular chamber being in fluid
communication with the
central passage for allowing wellbore fluid to flow into and enable fluid
pressurization of the
annular chamber to prevent subsequent fluid, particulates and/or slurry
material from flowing
into the annular region, and where the sleeve port is positioned within the
annular chamber
when in the first position.
[029] According to a possible implementation, the valve assembly further
includes a flow
control device, where the flow control device is integrated in the fluid
pathway when the valve
sleeve is in the operational position.
[030] According to a possible implementation, the flow control device is
provided within the
annular chamber when the valve sleeve is in the closed position.
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[031] According to a possible implementation, the flow control device
comprises a screen
superposed with the sleeve port for enabling screened fluid communication
between the
reservoir and the annular region.
[032] According to a possible implementation, the flow control device
comprises a directional
control valve device provided within the annular region to prevent fluid flow
in at least one
direction between the central passage and the reservoir.
[033] According to a possible implementation, the top sleeve is slidable
within the valve
housing to an open position where the housing port is in fluid communication
with the central
passage, and where fluid flow from the reservoir into the annular region is
prevented.
[034] According to a possible implementation, the subsequent fluid,
particulates and/or slurry
material comprises cement, and the wellbore fluid comprises brine, water,
drilling mud or a
combination thereof.
[035] According to another aspect, a valve assembly for integration within a
wellbore string
disposed along a wellbore defined within a subterranean reservoir is provided.
The valve
assembly includes a valve housing comprising an outer wall defining a central
passage
therethrough and having a housing port extending through the outer wall; a
valve sleeve
assembly operatively mounted within the valve housing and comprising a bottom
sleeve
slidable within the central passage between a closed position occluding the
housing port, and
an open position; a top sleeve defining an annular region between an outer
surface thereof
and an inner surface of the outer wall, the top sleeve being slidable within
the valve housing
between (i) a first position where a downhole end of the top sleeve is axially
spaced from the
housing port, and (ii) a second position where the down hole end at least
partially extends over
the housing port; and a flow-controlling sleeve having a sealed end sealingly
engaging the
inner surface of the outer wall to define an annular chamber within the
annular region, the
flow-controlling sleeve having a sleeve port and a flow control device
proximate the sleeve
port, the flow-controlling sleeve being slidable within the valve housing
between (i) a shrouded
position where the sleeve port and flow control device are provided within the
annular
chamber, and (ii) a flow-controlling position where the sleeve port is in
fluid communication
with the housing port to define a fluid pathway along which fluids are
flowable from the
reservoir through the housing port, through the sleeve port and into the
central passage. The
annular chamber being in fluid communication with the central passage for
allowing wellbore
fluid to flow into and enable fluid pressurization of the annular chamber to
prevent subsequent
fluid, particulates and/or slurry material from flowing into the annular
region, and where the
flow control device is provided along the fluid pathway when in the flow-
controlling position.
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[036] According to a possible implementation, the downhole end of the top
sleeve is adapted
to prevent fluid communication between the sleeve port and the central passage
when in the
second position, and wherein the fluid pathway is defined by moving the top
sleeve from the
second position to the first position.
[037] According to a possible implementation, the flow-controlling sleeve
comprises an
internal shoulder proximate the sealed end and extending into the central
passage, the top
sleeve being adapted to engage the internal shoulder to push the flow-
controlling sleeve,
whereby moving the top sleeve from the first position to the second position
correspondingly
displaces the flow-controlling sleeve from the shrouded position to the flow-
controlling
position.
[038] According to a possible implementation, the flow-controlling sleeve
comprises a
latching mechanism configured to releasably connect the flow-controlling
sleeve to the outer
wall when the flow-controlling sleeve is in one of the shrouded position and
the flow-controlling
position.
[039] According to a possible implementation, the latching mechanism is
adapted to retain
the flow-controlling sleeve in the flow-controlling position when moving the
top sleeve from the
second position to the first position.
[040] According to a possible implementation, the flow control device
comprises a screen
superposed with the sleeve port to allow fluid flow from the reservoir through
the screen and
into the central passage, the screen being configured to prevent various
particulates from
entering the valve housing and/or the central passage.
[041] According to another aspect, a valve assembly for integration within a
wellbore string
disposed along a wellbore defined within a subterranean reservoir is provided.
The valve
assembly includes a valve housing comprising an outer wall defining a central
passage
therethrough and having a housing port extending through the outer wall; a
valve sleeve
assembly operatively mounted within the valve housing and defining an annular
region within
the valve housing, the valve sleeve assembly comprising a valve sleeve having
a sleeve port
and being slidable within the valve housing between (i) a first position where
a downhole end
of the valve sleeve sealingly engages an inner surface of the outer wall to
define an annular
chamber within the annular region, and (ii) an operational position where the
sleeve port is in
fluid communication with the housing port to define a fluid pathway along
which fluids are
flowable from the reservoir into the central passage; and a flow control
device provided within
the annular region and being operable to control a flow of fluids along the
fluid pathway when
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Date Recue/Date Received 2022-09-28
the valve sleeve is in the operational position. The annular chamber being in
fluid
communication with the central passage for allowing wellbore fluid to flow
into and enable fluid
pressurization of the annular chamber to prevent subsequent fluid,
particulates and/or slurry
material from flowing into the annular region, and where the sleeve port is
positioned within
the annular chamber when in the first position.
[042] According to another aspect, a method of operating a well for primary
production of
hydrocarbons is provided. The method includes running a wellbore string
provided with one
or more valve assemblies as defined above down the well; pressurizing the
annular chamber
to create a pressure balance between the annular chamber and the central
passage; pumping
cement slurry down the wellbore string for cementing the wellbore string down
the well; shifting
one or more valve sleeves for operating the valve assembly in the open
configuration; injecting
fracturing fluid through the housing port for fracturing the wellbore;
shifting one or more valve
sleeves for defining a production fluid pathway along which reservoir fluid is
flowable through
the housing port, through the annular region provided with the flow control
device and into the
central passage.
BRIEF DESCRIPTION OF DRAWINGS
[043] Figure 1 is a transverse cut view of a wellbore with downhole components
integrated
along a wellbore string in a horizontal section extending in a reservoir,
according to an
implementation.
[044] Figure 2 is a perspective view of a valve assembly comprising a housing
port to enable
fluid communication between the wellbore and the wellbore string, according to
an
implementation.
[045] Figure 3 is a side view of the valve assembly shown in Figure 2.
[046] Figure 4 is a cross-sectional view of the valve assembly shown in Figure
3, showing a
pair of valve sleeves operatively coupled along a passage of the valve
assembly, according
to an implementation.
[047] Figures 4A, 4B and 4C are enlarged views of portions of Figures 4, 4A
and 4B
respectively, showing a fluid flowpath enabling fluid flow into an annular
region, according to
an implementation.
[048] Figure 5 is a cross-sectional view of the valve assembly, showing the
valve assembly
in an open configuration, where a bottom sleeve is spaced from the housing
port, according
to an implementation.
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Date Recue/Date Received 2022-09-28
[049] Figure 5A is an enlarged view of the housing port shown in Figure 5,
showing a fluid
flowpath for fluids being injected into the surrounding reservoir, according
to an
implementation.
[050] Figure 6 is a cross-sectional view of the valve assembly, showing the
valve assembly
in a flow-restricted configuration, according to an implementation.
[051] Figure 6A is an enlarged view of the housing port shown in Figure 6,
showing a fluid
pathway provided with a flow control device for controlling fluid flow of
fluid being produced
from the surrounding reservoir, according to an implementation.
[052] Figures 7 and 8 are respectively a perspective view and a side view of a
top sleeve,
showing a sleeve port defined therethrough, according to an implementation.
[053] Figure 8A is an enlarged view of a portion of Figure 8, showing
circumferential
openings defined in the sleeve port, according to an implementation.
[054] Figure 9 is an exploded view of the top sleeve shown in Figure 7,
showing components
of a flow control device, according to an implementation.
[055] Figure 10 is an enlarged cross-sectional view of the top sleeve shown in
Figure 6A,
showing the flow control device comprising an axial check valve device located
in the annular
region, according to an implementation.
[056] Figures 11 to 12A are an alternate implementation of the top sleeve,
showing flow
control device comprising a radial check valve device, according to an
implementation.
[057] Figure 13 is a front view of the top sleeve shown in Figure 11.
[058] Figure 14 is a cross-section view taken along line 14-14 in Figure 13,
showing the
radial check valve device coupled about the top sleeve, according to an
implementation.
[059] Figure 14A is an enlarged view of a component of the radial check valve
device,
according to an implementation.
[060] Figure 15 is an exploded view of the top sleeve shown in Figure 11,
showing the radial
check valve device coupled to a central portion of the top sleeve, according
to an
implementation.
Date Recue/Date Received 2022-09-28
[061] Figures 16 to 24 illustrate alternate implementations of the flow
control device,
including an axial poppet check valve (Figures 16 to 18), a reed type check
valve (Figures 18
to 24), according to possible implementations.
[062] Figure 25 is a cross-sectional view of an alternate implementation of
the valve
assembly, showing a single valve sleeve operable between a closed position and
a screened
position, according to an implementation.
[063] Figure 26 is a cross-sectional view of an alternate implementation of
the valve
assembly, showing a single valve sleeve operable between a closed position, an
open position
and a screened position, according to an implementation.
[064] Figures 27 to 30 are cross-sectional views of an alternate
implementation of the valve
assembly, showing the valve assembly in a closed configuration (Figures 27 and
27A), an
open configuration (Figure 28), a secondary closed configuration (Figure 29)
and a screened
configuration (Figure 30), according to possible implementations.
[065] Figure 31 is a cross-sectional view of an alternate implementation of
the valve
assembly, showing a dual-barrel valve assembly in a closed configuration,
according to an
implementation. Figure 31A is an enlarged view of a portion of the valve
assembly shown in
Figure 31.
[066] Figure 32 is a cross-sectional view of the valve assembly shown in
Figure 31, showing
the valve assembly in an open configuration, according to an implementation.
Figure 32A is
an enlarged view of a portion of the valve assembly shown in Figure 32.
[067] Figure 33 is a cross-sectional view of the valve assembly shown in
Figure 31, showing
the valve assembly in a secondary closed configuration, according to an
implementation.
Figure 33A is an enlarged view of a portion of the valve assembly shown in
Figure 33.
[068] Figure 34 is an enlarged view of a bottom sleeve shown in Figure 32,
showing a screen
provided at an end of the bottom sleeve, and a lock ring provided about the
bottom sleeve,
according to possible implementations.
[069] Figure 35 is a cross-sectional view of the valve assembly shown in
Figure 31, showing
the valve assembly in a screened configuration, according to an
implementation. Figure 35A
is an enlarged view of a portion of the valve assembly shown in Figure 35.
[070] Figure 36 is a cross-sectional view of an alternate implementation of
the valve
assembly, showing a valve assembly with a fixed barrel and a movable barrel,
according to
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Date Recue/Date Received 2022-09-28
an implementation. Figure 36A is an enlarged view of a portion of the valve
assembly shown
in Figure 36, showing the valve assembly in a closed configuration, according
to a possible
implementation.
[071] Figure 37 is a cross-sectional view of the valve assembly shown in
Figure 36, showing
the valve assembly in an open configuration, according to an implementation.
Figure 37A is
an enlarged view of a portion of the valve assembly shown in Figure 37.
[072] Figure 38 is a cross-sectional view of the valve assembly shown in
Figure 36, showing
the valve assembly in a screened configuration, according to an
implementation. Figure 38A
is an enlarged view of a portion of the valve assembly shown in Figure 38.
[073] Figure 39 is a perspective view of an alternate implementation of a
valve assembly,
showing a dual-barrel valve assembly with a rotating barrel, according to an
implementation.
[074] Figure 40 is a cross-sectional view of the valve assembly shown in
Figure 39, showing
the valve assembly in a closed configuration, according to a possible
implementation. Figure
40A is an enlarged view of a portion of the valve assembly shown in Figure 40.
[075] Figure 41 is a top view of the valve assembly shown in Figure 39,
showing a guiding
pin engaged in an elongated slot for positioning the valve assembly in the
closed configuration,
according to an implementation.
[076] Figure 41A is a cross-sectional view of the valve assembly shown in
Figure 41,
showing a pair of guiding pins engaging a bottom end of respective elongated
slots, according
to an implementation.
[077] Figure 42 is a cross-sectional view of the valve assembly shown in
Figure 39, showing
the valve assembly in an open configuration, according to a possible
implementation. Figure
42A is an enlarged view of a portion of the valve assembly shown in Figure 42.
[078] Figure 43 is a top view of the valve assembly shown in Figure 39,
showing the guiding
pin engaged in a corner of an angled surface for positioning the valve
assembly in the open
configuration, according to an implementation.
[079] Figure 43A is a cross-sectional view of the valve assembly shown in
Figure 43,
showing a pair of guiding pins engaging respective corners, according to an
implementation.
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Date Recue/Date Received 2022-09-28
[080] Figure 44 is a cross-sectional view of the valve assembly shown in
Figure 39, showing
the valve assembly in a screened configuration, according to a possible
implementation.
Figure 44A is an enlarged view of a portion of the valve assembly shown in
Figure 44.
[081] Figure 45 is a top view of the valve assembly shown in Figure 39,
showing the guiding
pin engaged in a second elongated slot for positioning the valve assembly in
the screened
configuration, according to an implementation.
[082] Figure 45A is a cross-sectional view of the valve assembly shown in
Figure 45,
showing a pair of guiding pins engaging respective second elongated slots,
according to an
implementation.
[083] Figure 46 is a cross-sectional view of an alternate implementation of
the valve
assembly, showing a dual-barrel valve assembly with an inflow control device
coupled about
a top barrel, according to an implementation. Figure 46A is an enlarged view
of a portion of
the valve assembly shown in Figure 46, showing the valve assembly in a closed
configuration,
according to a possible implementation.
[084] Figure 47 is a cross-sectional view of the valve assembly shown in
Figure 46, showing
the valve assembly in an open configuration, according to an implementation.
Figure 47A is
an enlarged view of a portion of the valve assembly shown in Figure 47.
[085] Figure 48 is a cross-sectional view of the valve assembly shown in
Figure 46, showing
the valve assembly in a flow-restricted configuration, according to an
implementation. Figure
48A is an enlarged view of a portion of the valve assembly shown in Figure 48.
[086] Figure 49 is a cross-sectional view of an alternate implementation of
the valve
assembly, showing a dual-barrel valve assembly with an isolated flow control
device coupled
about a top barrel, according to an implementation. Figure 49A is an enlarged
view of a portion
of the valve assembly shown in Figure 49, showing the valve assembly in a
closed
configuration, according to a possible implementation.
[087] Figure 50 is a cross-sectional view of the valve assembly shown in
Figure 49, showing
the valve assembly in an open configuration, according to an implementation.
Figure 50A is
an enlarged view of a portion of the valve assembly shown in Figure 50.
[088] Figure 51 is a cross-sectional view of the valve assembly shown in
Figure 49, showing
the valve assembly in a flow-restricted configuration, according to an
implementation. Figure
51A is an enlarged view of a portion of the valve assembly shown in Figure 51,
showing an
13
Date Recue/Date Received 2022-09-28
inflow control device coupled between the top barrel and the flow control
device, according to
an implementation.
[089] Figure 52 is a cross-sectional view of an alternate implementation of
the valve
assembly, showing a dual-barrel valve assembly with a latching assembly for a
top barrel and
a screen, according to an implementation. Figure 52A is an enlarged view of a
portion of the
valve assembly shown in Figure 52, showing the valve assembly in a closed
configuration,
according to a possible implementation.
[090] Figure 53 is a cross-sectional view of the valve assembly shown in
Figure 52, showing
the valve assembly in an open configuration, according to an implementation.
Figure 53A is
an enlarged view of a portion of the valve assembly shown in Figure 53.
[091] Figure 54 is a cross-sectional view of the valve assembly shown in
Figure 52, showing
the valve assembly in a flow-restricted configuration, according to an
implementation. Figure
54A is an enlarged view of a portion of the valve assembly shown in Figure 54.
[092] Figure 55 is a cross-sectional view of the valve assembly shown in
Figure 52, showing
the valve assembly in a screened configuration, according to an
implementation. Figure 55A
is an enlarged view of a portion of the valve assembly shown in Figure 55.
[093] Figure 56 is a cross-sectional view of an alternate implementation of
the valve
assembly, showing a dual-barrel valve assembly with a flow regulator,
according to an
implementation. Figure 56A is an enlarged view of a portion of the valve
assembly shown in
Figure 56, showing the valve assembly in a closed configuration, according to
a possible
implementation.
[094] Figure 57 is a cross-sectional view of the valve assembly shown in
Figure 56, showing
the valve assembly in an open configuration, according to an implementation.
Figure 57A is
an enlarged view of a portion of the valve assembly shown in Figure 57.
[095] Figure 58 is a cross-sectional view of the valve assembly shown in
Figure 56, showing
the valve assembly in a flow-restricted configuration, according to an
implementation. Figure
58A is an enlarged view of a portion of the valve assembly shown in Figure 58.
[096] Figure 59 is a cross-sectional view of the valve assembly shown in
Figure 56, showing
the valve assembly in a screened configuration, according to an
implementation. Figure 59A
is an enlarged view of a portion of the valve assembly shown in Figure 59.
14
Date Recue/Date Received 2022-09-28
[097] Figure 60 is a side view of the flow regulator, showing a plurality of
grooves defined
along a tubular body, according to an implementation.
[098] Figure 61 is a cross-sectional view of an alternate implementation of
the valve
assembly, showing a dual-barrel valve assembly with a check valve, according
to an
implementation. Figure 61A is an enlarged view of a portion of the valve
assembly shown in
Figure 61, showing the valve assembly in a closed configuration, according to
a possible
implementation.
[099] Figure 62 is a cross-sectional view of the valve assembly shown in
Figure 61, showing
the valve assembly in an open configuration, according to an implementation.
Figure 62A is
an enlarged view of a portion of the valve assembly shown in Figure 62.
[100] Figure 63 is a cross-sectional view of the valve assembly shown in
Figure 61, showing
the valve assembly in a flow-restricted configuration, according to an
implementation. Figure
63A is an enlarged view of a portion of the valve assembly shown in Figure 63.
[101] Figure 64 is a cross-sectional view of the valve assembly shown in
Figure 61, showing
the valve assembly in a screened configuration, according to an
implementation. Figure 64A
is an enlarged view of a portion of the valve assembly shown in Figure 64.
[102] Figure 65 is a perspective view of a valve sleeve provided with a flow
restriction
component in the form of a tortuous channel, according to an implementation.
DETAILED DESCRIPTION
[103] As will be explained below in relation to various implementations, the
present
disclosure describes devices, systems and methods for various operations, such
as the
injection of fluids and the recovery of hydrocarbon material from a
subterranean reservoir. The
present disclosure more specifically relates to a well completion system, and
corresponding
structural features, operable for the injection and recovery of fluids, such
as hydrocarbons, via
a wellbore. The well completion system is configured to be installed within
the wellbore and
includes a wellbore string comprising one or more valve assemblies operable to
inject fluid
(e.g., a fluid for stimulating hydrocarbon production via a drive process,
such as waterflooding,
or via a cyclic process, such as "huff and puff') into the subterranean
reservoir, and also to
produce reservoir fluids. In other words, the valve assemblies can be
configured to enable
both injection and production operations within the reservoir. The valve
assembly can also
include an annular chamber in which an apparatus, a subsystem or a device,
such as a flow
Date Recue/Date Received 2022-09-28
control device, is provided, enabling the device to be deployed downhole along
with the
wellbore string (e.g., instead of being run downhole as part of a subsequent
work string).
[104] The valve assembly can be shifted, operated, or otherwise moved, into
different
configurations to define different flow pathways at different stages of
operation. As will be
described further below, the valve assembly can be adapted to define a first
flow pathway and
a second flow pathway which can be defined by two partially independent
passages along
which fluid can flow. In other words, and for example, the first and second
flow pathways are
not identical (e.g., structurally), but can share common components, such as
inlets.
[105] In some implementations, the valve assembly includes a valve housing
having a
central passage therethrough and a plurality of frac ports extending radially
through an outer
wall thereof for establishing fluid communication between the passage and the
reservoir. The
valve assembly further includes a pair of sleeves, which can be slidably
mounted within the
housing and configured to selectively close and open the frac ports. The
housing and the
sleeves define the at least two fluid pathways which can be at least partially
isolated from one
another, and along which fluid flows to and/or from the reservoir. As will be
described further
below, one of the pathways includes the annular chamber provided with the flow
control
device, such that fluid is confined to flow through the annular chamber and
where fluid flow is
at least partially controlled by the flow control device.
[106] It will be understood that the valve assembly described herein can be
used in relation
with cemented wellbore string applications, such as with multistage fracturing
(also referred to
as "fracking") operations, for example. In fracturing operations, the wellbore
can first be dug
out (e.g., drilled) and lined with casing, and then cement slurry can be
pumped down the
casing towards a toe of the wellbore and back up an annulus defined between
the casing and
the reservoir (i.e., the walls of the wellbore). In order to push the cement
slurry past the toe
and into the annulus, a wiper plug can be pumped down the casing to
effectively wipe the
slurry from the interior of the wellbore. Once within the annulus, the cement
can be allowed to
cure, thus cementing the casing within the wellbore.
[107] In the context of the present disclosure, the valve assembly can be
installed between
lengths of casing at desired locations. These locations can be determined
based on where
perforations would have been created using a perforating gun, for example.
After the casing
and valve assemblies are in place down the wellbore, the casing and valve
assemblies are
cemented in place using cementing techniques such as those noted above. It is
noted that the
cementing process can interfere with the operation of the sleeves or other
moving parts of the
valve assembly. The sleeves can therefore be designed to accommodate the
cementing
16
Date Recue/Date Received 2022-09-28
process whereby cement is prevented from entering any ports, slots, recesses
and the like,
that might not be cleaned by the wiper plug, such as the annular chamber, for
example.
Furthermore, in order to prevent the sleeves from being moved by the wiper
plug (or by
subsequent well equipment, cleaning, etc.), the sleeves can be held in
position by shear pins
or other securing mechanisms, as will be described further below.
[108] The valve assembly can further include interstices defined between
various
components thereof (the sleeve, the housing, etc.) which establish fluid
communication
between a central passage of the valve assembly and the annular chamber. The
interstices
are sized and adapted to allow fluid, e.g., water, gas, etc., to flow into and
pressurize the
annular chamber. The valve assembly also includes an arrangement of seals
which prevents
fluid from flowing out of the annular chamber, which defines a dead-end
annular chamber and
facilitates pressurization thereof. As such, when pumping slurry material,
e.g., cement, down
the wellbore in order to secure the wellbore string, the pressurized annular
chamber prevents
the cement from flowing into the dead-end annular chamber, thereby preventing
cement from
contacting and potentially damaging the flow control device. The fluid which
initially flows into
the annular chamber can be residual fluid from drilling out the wellbore
(e.g., brine, water,
drilling mud, etc.), which pressurizes the annular chamber and prevents
subsequent fluid or
material being pumped downhole from flowing into the annular chamber.
[109] It should thus be noted that the valve assembly is shaped, sized and
adapted to be
integrated as part of the wellbore string, and is secured in place (e.g.,
cemented) down the
wellbore along with the wellbore string. The valve assembly is further adapted
to isolate, or
"shroud" components provided within the dead-end annular chamber while the
valve assembly
is in the run-in, or closed configuration. The valve assembly is operable
between various
configurations for allowing fluid to be injected within the reservoir, and
reservoir fluid to be
produced from the reservoir into the valve assembly for ultimate recovery to
surface. In some
implementation, the valve assembly is a dual-barrel valve assembly
configurable between the
closed configuration, where the ports of the valve housing are occluded, the
open
configuration, where the ports are open and fluid communication can be
established between
the reservoir and the fluid passage of the wellbore string, and a flow
restricted configuration,
where the flow control device is moved and aligned with the ports of the
housing, thereby
creating a fluid pathway which cooperates with the flow control device. As
mentioned above,
in some implementations, the flow control device is provided within the
annular chamber,
therefore it is noted that the fluid pathway created when in the flow
restricted configuration can
flow through the annular chamber defined between the valve sleeve and the
exterior housing.
17
Date Recue/Date Received 2022-09-28
[110] In an exemplary implementation, the flow control device includes a
screened
configured to have fluid produced from the reservoir flow through it, thus
preventing large
particulates from entering the wellbore string and being produced to surface.
The flow control
device can alternatively, or additionally include a check valve which prevents
fluid flow in a
specific direction. For example, the valve assembly can be operated as a
production-only
valve assembly, where the check valve prevents the injection of fluid into the
reservoir when
the valve assembly is in the flow restricted configuration. The wellbore
string can include
multiple valve assemblies and can thus be operated for various applications,
such as
asynchronous frac-to-frac operations, where the reservoir is fractured, the
valve assemblies
are shifted in the open configuration for the injection of fluid into the
reservoir, and then shifted
in the flow restricted configuration to initiate a screened production of
reservoir fluids. The well
completion system can also be used in other applications, such as geothermal
applications. It
is also noted that the well completion system can be used in applications
where the formation
is not required to be fractured but has a permeability that enables fluid
injection or includes
naturally formed fractured.
[111] It should also be noted that enabling an initial ingress of fluids
within the annular region
(e.g., within the annular chamber) creates a pressure-balanced system between
the annular
chamber and the central passage of the valve assembly. This pressure-balanced
system
enables the use of valve sleeves having relatively thin walls since the wall
is not submitted to
a pressure differential between the annular chamber and the central passage.
The pressure-
balanced system therefore assists in preventing collapse of the valve assembly
during
pressurization of the annular region, during the cementing process and during
various
operations of the valve assembly. It should be understood that the annular
chamber is in fluid-
pressure communication with the central passage, and that this pressure-
balanced system
also prevents subsequent fluids or materials from flowing into the annular
chamber, and
instead flow towards an opened port, for example. Therefore, components
provided within the
annular chamber are protected from potentially damaging fluids and/or
material, such as
cement, for example.
[112] It is noted that the completion system and the valve assemblies
described herein can
be implemented in various wellbores, formations, and for various applications.
In some
implementations, the wellbore can be straight, curved, or branched, and can
have various
wellbore sections. A wellbore section should be considered to be an axial
length of a wellbore.
A wellbore section can be characterized as "vertical" or "horizontal" even
though the actual
axial orientation can vary from true vertical or true horizontal, or can tend
to undulate or
corkscrew or otherwise vary. The term "horizontal", when used to describe a
wellbore section,
18
Date Recue/Date Received 2022-09-28
refers to a horizontal or highly deviated wellbore section as understood in
the art, such as a
wellbore section having a longitudinal axis that is between 70 and 110 degrees
from vertical.
For simplicity, it is noted that most of the conduits, channels, passageways,
pipes, tubes
and/or other similar components referred to in the present disclosure have a
cross-section that
is preferably circular or annular, although it should be appreciated that
other shapes are also
possible.
[113] With reference to Figures 1 and 2, a wellbore 10 extends from the
surface 12 and into
a reservoir 14. A well completion system 20 including one or more valve
assemblies 100 can
be integrated as part of a wellbore string 30 extending within the wellbore
10. The wellbore
string 30 defines a wellbore string passage 30A for conducting fluid between
the surface 12
and the reservoir 14. In some implementations, the valve assemblies 100 each
include at least
one passage allowing fluid flow therethrough. It should therefore be
understood that the valve
assemblies include passages that can form part of the wellbore string passage
30A along at
least a portion of the wellbore, such that fluid communication between the
surface 12 and the
reservoir 14 can be established via the valve assemblies 100. More
specifically, and as will
be described below, the valve assembly 100 can be provided with one or more
ports at
respective locations along the wellbore for establishing fluid communication
between the
wellbore string 30 and the reservoir 14. It is also noted that conduits 31 of
the wellbore string
30 can be located on either end of the valve assembly 100 and can be coupled
to respective
ends thereof by any suitable method. It is also possible to connect some or
all of the valve
assemblies end-to-end without any intervening conduits 31.
[114] As seen in Figure 1, the wellbore 10 can include a horizontal wellbore
section 16 having
a toe 15 and a heel 17 at respective ends thereof. It should be understood
that, as used herein,
the expression "toe" refers to an end region of the horizontal wellbore
section, such as the
end region furthest from surface. Similarly, the expression "heel", as used
herein, refers to
the opposite end region of the horizontal section, i.e., the beginning of the
horizontal wellbore
section 16, and may include at least part of the curved transition section
between the
horizontal and vertical sections of the wellbore 10. Therefore, the
expressions "downhole" and
"uphole" used herein can refer to directional features, whereby uphole is in a
general direction
towards the heel 17, and downhole is in a general direction towards the toe
15.
[115] With reference to Figures 3 to 4, in addition to Figures 1 and 2, the
valve assembly 100
includes a valve housing 102 having an outer tubular wall 103 defining a
central passage 106
for enabling fluid communication through the housing 102 (e.g., axially
through the housing
102). In other words, the central passage 106 can act as a fluid passage
configured to allow
a flow of fluid therethrough and along the wellbore string. Referring more
specifically to Figures
19
Date Recue/Date Received 2022-09-28
2 and 3, the valve housing 102 includes a top sub 108 provided at an uphole
end 109 of the
outer wall 103, and a bottom sub 110 provided at a downhole end 111 thereof.
The top and
bottom subs 108, 110 are secured to the outer wall 103 via interference fit,
although other
connection methods can be used, such as via threaded connectors, via a slot
and key
connection or via fasteners. The top and bottom subs can also be connected
between lengths
of conduits or other components of the valve assembly 100, thereby enabling
the integration
of the valve assembly with the wellbore string 30.
[116] The valve housing 102 also includes a housing port 112 extending through
the outer
wall 103 and through which fluid communication between the central passage 106
and an
environment external to the housing 102 (e.g., the reservoir 14) is
established. In some
implementations, the housing port 112 includes a plurality of openings 114
(e.g., two, three,
four, six, eight, etc.) defined through the outer wall 103, although a single
opening could be
used. The openings 114 can be formed as generally straight and tubular
openings through the
outer wall 103, although any other suitable shapes, configurations and/or
number of openings
can be used. As seen in Figures 2 and 3, the openings 114 can be distributed
(e.g., evenly/at
regular intervals) about a circumference of the outer wall 103. The openings
can also have
different cross-sectional areas and shapes, e.g., cylindrical, frustoconical,
tapered toward or
away from the reservoir, etc. In some implementations, the openings can also
be open during
deployment downhole or could have a temporary plug or cap that is expelled due
to the
pressure of the fracturing fluid during the fracturing operation. It should be
noted that the valve
assembly 100 can be used for fracturing operations, where fracturing fluid is
injected into the
reservoir via the housing port 112. As such, it is appreciated that the
openings 114 of the
housing port 112 can correspond to frac ports.
[117] In some implementations, the valve assembly 100 is configurable in a
plurality of
operational configurations, and each one of the operational configurations,
independently,
corresponds to a state of fluid communication, via the housing port 112,
between the central
passage 106 and the surrounding reservoir. In other words, fluid flow through
the housing port
112 can be at least partially controlled via a change in the operational
configuration of the
valve assembly 100 (e.g., a change from a first operational configuration to a
second
operational configuration). In some implementations, the valve assembly 100
can be
configurable between a closed configuration (seen in Figure 4), where the
housing port 112 is
blocked or closed; an open configuration (seen in Figure 5), where the housing
port 112 is
unobstructed or open and where fluid can be injected within the reservoir via
the housing port
112; and a flow-restricted configuration (seen in Figure 6), where production
fluid is produced
from the reservoir and is confined to flow along a fluid pathway provided with
a flow control
Date Recue/Date Received 2022-09-28
device. The valve assembly 100 can also move to a configuration where
production fluid is
received within the passage 106 but does not flow along the fluid pathway if
the latter is kept
enclosed and sealed. In order to operate the valve assembly 100 in these
various
configurations, the valve assembly 100 includes one or more inner sleeves, or
valve sleeves
120, operatively mounted within the housing 102 and displaceable between
various positions.
[118] The sleeves 120 can be provided with various features and/or in various
configurations
in order to be displaceable and to provide the different (e.g., non-identical)
flow pathways for
fracturing, injecting and producing. Some features and implementations of
possible sleeve
arrangements are described below.
[119] Still referring to Figure 4, and with further reference to Figures 4A,
the valve sleeves
120 are operatively mounted within the housing 102 and are operable for
selectively closing
and opening the housing port 112. In this implementation, the valve sleeves
120 include a pair
of valve sleeves slidably mounted within the housing 102 for moving axially
therealong (e.g.,
sliding or shifting along inner surfaces 105 of the housing within the passage
106). More
particularly, the valve sleeves 120 include a bottom sleeve 122 (or downhole
sleeve) mounted
within a downhole portion of the housing 102, and a top sleeve 124 (or uphole
sleeve) mounted
within an uphole portion of the housing. The valve sleeves 120 can be
substantially aligned
with one another and both include a bore therethrough such that fluid can flow
freely along the
valve assembly 100 (e.g., from one sleeve to the other and through the
housing). The valve
sleeves 120 can be independently displaced with respect to one another along
the passage
106 and can be arranged in various positions in order to direct fluid flow
into predetermined
fluid pathways of the valve assembly 100.
[120] The valve sleeves 120 can be mounted within the housing 102 in a manner
allowing
the sleeves to shift from one position to another. It should be understood
that the expression
"shift" can refer to the displacement of the valve sleeves 120 using a
shifting tool, for example,
or a self-shifting mechanism provided as part of the valve assembly 100 such
that the sleeves
can be toollessly operated, for example. As seen in Figures 4 and 4A, the
valve assembly 100
can be operated in a closed configuration, with the bottom sleeve 122 being
mounted in the
housing in an occluding, or closed position, where the housing port 112 is
blocked by the
bottom sleeve 122. Moreover, the top sleeve 124 can be mounted uphole of the
bottom sleeve
122 in a first position, or "run-in-hole position". It is appreciated that,
when the bottom sleeve
122 is in the closed position, the top sleeve 124 remains in the first
position. As will be
described further below, the top sleeve 124 is mounted within the valve
housing 102 in a
manner defining an annular region 130 between an outer surface of the top
sleeve 124 and
the inner surface 105 of the outer wall 103. In some implementations, the top
and bottom
21
Date Recue/Date Received 2022-09-28
sleeves 122, 124 can be shaped and configured to sealingly engage one another
and/or the
outer wall 103 such that fluid flow is prevented, or at least reduced, along
gaps defined
between the housing and the sleeves. While deploying a shifting tool can be a
preferred way
to shift the sleeves, in an alternative scenario the sleeves can be shifted or
otherwise displaced
remotely or via the use of other devices.
[121] With reference to Figures 4t0 4C, when the bottom sleeve 122 is in the
closed position,
a portion of the bottom sleeve 122 covers the housing port 112 such that fluid
cannot flow
therethrough. The bottom sleeve 122 can sealingly engage the inner surface of
the outer wall
103 such that fluid flow is prevented, or at least reduced, within interstices
defined by the
housing and the bottom sleeve 122. In some implementations, the valve assembly
100 can
include additional elements adapted to prevent, or at least reduce, movement
of the sleeves
and/or fluid flow into certain regions. For example, in the illustrated
implementation, the valve
assembly 100 includes seals 140 provided between the sleeves and the outer
wall 103. For
example, in this implementation, a seal 140 can be provided at the uphole end
of the bottom
sleeve 122 to prevent fluid communication between the central passage 106 and
an
environment surrounding the valve assembly 100 when the valve assembly 100 is
in the
closed configuration.
[122] Still referring to Figures 4 to 4C, when in the closed configuration,
the top sleeve 124
is positioned within the valve housing 102 in the first position, proximate
the top sub 108. More
specifically, in this implementation, the uphole end 124a of the top sleeve
124 can abut the
top sub 108, with the downhole end 124b having a greater outer diameter to
engage the inner
surface 105 of the outer wall 103. The outer wall 103 can also include an
internal protrusion,
such as an inner ring 107, extending inwardly within the central passage 106
to enable
engagement with the uphole end 124a of the top sleeve 124. As such, the top
sleeve 124 and
the outer wall 103 can define an annular chamber 132 within the annular region
130, where
the annular chamber 132 is defined radially between the outer surface of top
sleeve 124 and
the inner surface 105 of the outer wall, and defined axially between the
downhole end 124b
of the top sleeve engaging the outer wall and the uphole end 124a of the top
sleeve engaging
the inner ring 107.
[123] The annular chamber 132 can be in fluid communication with the central
passage 106
via one or more interstices 135 defined between the components of the valve
assembly 100.
As seen in Figure 4B and 4C, the interstices 135 can define a restricted
flowpath (A) along
which fluid can flow from the central passage 106 to the annular chamber 132.
The interstices
135 are sized and adapted to allow fluid (e.g., water) to flow into and
pressurize the annular
chamber 132 while also preventing particulates and/or slurry material (e.g.,
cement) from
22
Date Recue/Date Received 2022-09-28
flowing into the annular chamber 132. As will be described further below, the
top sleeve 124
includes a sleeve port 126 adapted to be aligned with the housing port 112 in
order to define
a fluid pathway for the production of reservoir fluids. The valve assembly 100
can also include
a flow control device 150 coupled to the top sleeve and positioned along the
fluid pathway,
within the annular region 130. The sleeve port 126 and flow control device 150
are illustratively
provided within the annular chamber 132 when the top sleeve 124 is in the
first position. As
such, it should be noted that the sleeve port 126 and flow control device 150
are isolated, or
at least partially protected from particulates and/or slurry material flowing
along the central
passage 106, such as cement when cementing the wellbore string down the
wellbore.
[124] Prior to being shifted, the valve sleeves 120 can be secured in their
respective run-in
positions using any suitable method. The valve sleeves 120 can be shaped and
configured to
engage inner surfaces 105 of the corresponding portion of the housing 102. For
example, the
valve sleeves 120 can have one or more sections having a greater outer
diameter for sealingly
engaging with the housing 102, and thus maintain the sleeves in position
(e.g., via a press-fit
connection). Alternatively, or additionally, the housing 102 can have portions
that extend
inwardly (i.e., into the passage 106) at predetermined sections for engaging
with
corresponding parts of the valve sleeves 120 and further securing or
stabilizing the valve
sleeves 120 in position. In some implementations, the valve sleeves 120 can be
secured in
position using one or more fasteners, such as shear pins 125 extending from
the housing 102
and engaging the valve sleeves 120. The shear pins 125 are configured to break
in order to
allow the valve sleeves 120 to be shifted between positions. In this
implementation, the shear
pins 125 are configured to retain the sleeves in their initial positions
during the completion of
the wellbore, and more specifically during cementing of the casing. In other
words, the shear
pins 125 are configured to retain the sleeves while the sleeves are being
installed along the
wellbore, and while the wiper plug cleans the interior of the wellbore, as
previously described.
[125] The valve assembly 100 can be run downhole in the closed configuration
(Figures 4t0
4C) where the housing port 112 is blocked and the flow control device is
shrouded within the
annular chamber in order to secure (e.g., cement) the wellbore string without
obstructing the
port 112 or damaging the flow control device. Once the wellbore string is
cemented, the valve
assembly 100 can be operated in an open configuration (Figure 5 and 5A) where
fluid
communication is established between the central passage 106 and the
reservoir. The open
configuration can also correspond to a fracturing configuration of the valve
assembly 100 in
order to initiate fracturing of the reservoir. Fracturing generally includes
injection of fracturing
fluid into the reservoir at high pressure for fracturing the subterranean
formation surrounding
the valve assembly. The injection of fluid causes the rock of the formation to
fracture, thereby
23
Date Recue/Date Received 2022-09-28
enabling the fluid to flow into the fractures. In this implementation, in
order to operate the valve
assembly 100 in the fracturing configuration, the bottom sleeve 122 can be
shifted to a non-
occluding position, or open position, in order to open the housing port 112.
In some
implementation, the bottom sleeve 122 is displaced in the downhole direction
until the housing
port 112 is open, thus allowing fluid to be injected into the reservoir.
However, it is appreciated
that other configurations are possible. Furthermore, it should be noted that
the top sleeve 124
preferably remains in the first position when operating the valve assembly 100
in the fracturing
configuration in order to maintain the housing port 112 open, and the
components isolated
within the annular chamber 132.
[126] With reference to Figures 5 and 5A, in this implementation, the valve
assembly 100
defines a fracturing fluid pathway (B) (which can also be referred to as an
injection fluid
pathway) along which the fluid (e.g., fracturing fluid, injection fluid, etc.)
flows to reach the
housing port 112. The fluid flowing along the fracturing fluid pathway (B)
enters the central
passage 106 via the top sub 108, flows through the top sleeve 124 and exits
the housing 102
(e.g., enters the reservoir) via the housing port 112. However, it is
appreciated that other
pathways and configurations are possible for routing the fracturing fluid to
the reservoir. As
described above, the fracturing fluid can be forced through the housing port
112 due to
pressure build-up within the housing 102 caused by the presence of a packer,
frac plug, or
other obstruction (not illustrated) deployed downhole of the valve assembly
10, for example.
Furthermore, once fracturing has occured, the bottom sleeve 122 can be shifted
uphole, back
to the closed position (as seen in Figure 4) to prevent back flow of the
fracturing fluid from the
formation and allow "healing" or equilibration of the reservoir prior to a
subsequent operation,
such as production.
[127] In some implementations, fluid production from the reservoir can be
initiated using a
pump coupled to the wellbore string configured to pump fluid (e.g.,
hydrocarbon-containing
fluid) uphole along the valve assembly 100 and the wellbore string for
recovery thereof at
surface. Production can be enabled by a downhole pump, a surface pump or
artificial lift, as
the case may be. It should be understood that production fluid can be
recovered when the
valve assembly 100 is in the so-called "fracturing configuration", whereby
fluid is pumped
through the housing port 112 into the housing 102 and follows the fracturing
fluid pathway (B)
in the opposite direction (e.g., uphole toward the surface). In some
implementations and for
some operations, the valve assembly 100 is indeed operated in this manner at
least for some
time. This operating mode can be referred to as a non-restricted production
mode, as the
annular chamber 132 remains isolated, and the production fluid pathway does
not flow through
the flow control device 150. However, as will be described below, the valve
assembly 100 can
24
Date Recue/Date Received 2022-09-28
be operated in a flow-restricted configuration, whereby a separate fluid
pathway is defined to
allow production fluid to flow from the reservoir to the wellbore string
through the annular
region, through (or around) the flow control device, and ultimately to
surface. It is noted that
all of the production fluid being recovered via a particular valve assembly
while in the flow-
restricted configuration can be routed to flow through the annular region,
although other
configurations are possible.
[128] Referring to Figures 6 and 6A, the flow-restricted configuration allows
production of
reservoir fluid via the wellbore string for recovery thereof at surface. More
specifically, the flow-
restricted configuration defines a production fluid pathway (C) along which
the production fluid
flows to reach the central passage 106 of the valve assembly 100. As seen in
Figures 6 and
6A, the top sleeve 124 can be disposed within the housing 102 in a manner
defining the
annular region 130 between at least a section of the top sleeve 124 and the
outer wall 103,
and more particularly between the outer surface of the top sleeve 124 and the
inner surface
105 of the outer wall 103. In some implementations, the top sleeve 124 and the
outer wall 103
are substantially concentric such that a relatively constant flow area is
defined through the
annular region 130. However, it is appreciated that other configurations are
possible, such as
having an annular region 130 with a varying flow area along the top 124, for
example, or
defining the production fluid pathway in other ways. In the illustrated
implementation, the
annular region 130 defines a notable portion of the production fluid pathway
(C) and is
configured to allow fluid flowing from the reservoir to reach the passage 106
during production.
[129] In some implementations, the flow-restricted configuration is achieved
by shifting the
top sleeve 124 downhole to a second position, such as a production position,
where the sleeve
port 126 is aligned with the housing port 112, thereby opening the annular
chamber 132 to the
reservoir. It is noted that positioning the top sleeve 124 in the production
position can push
the bottom sleeve 122 to the open position simultaneously. Furthermore, in
this
implementation, shifting the top sleeve 124 to the production position
establishes fluid
communication between the reservoir and at least a portion of the annular
region 130 via the
housing port 112, thereby opening the flow control device 150 to fluid flow.
However, it is
appreciated that other configurations are possible for establishing fluid
communication
between the reservoir and the annular region 130. For example, the housing 102
can be
provided with a second set of ports configured to be open upon operation of
the valve
assembly 100 to the flow-restricted configuration so that the second set of
ports communicates
with the reservoir and the annular region.
[130] In this implementation, the flow control device 150 is at least
partially housed within
the annular chamber 132 and is configured to control the fluid flowing through
the annular
Date Recue/Date Received 2022-09-28
region 130 during production. As mentioned above, the annular chamber 132 is
at least
partially isolated from the rest of the valve assembly 100 prior to shifting
the top sleeve 124 to
the production position. In some implementations, the top sleeve 124 can be
shaped and
configured to sealingly engage the housing 102 at the downhole end 124b
thereof. For
example, the top sleeve 124 can be provided with a pair of seals 140 at the
downhole end
thereof on either side of the sleeve port 126. As such, fluid flowing through
the housing port
112 is substantially confined to flow through the sleeve port 126 and along
the annular region
130. In other words, the entire volume of production fluid flows into the
housing, along the
annular region 130 through the annular chamber 132 and past the uphole end of
the top sleeve
124 to reach the central passage 106 (e.g., fluid flowpath (C) illustrated in
Figure 6A). It is
noted that in the production position, the uphole end of the top sleeve 124
can be free of
contact from the housing 102 to allow fluid from within the annular region 130
to flow into the
central passage 106 by simply flowing past the uphole edge of the top sleeve
124.
[131] In some implementations, the flow control device 150 can include a
directional control
valve device 152 adapted to prevent fluid flow in at least one direction
between the central
passage 106 and the reservoir, when the top sleeve 124 is in the production
position. For
example, in this implementation, the directional control valve device 152 is
adapted to prevent
fluid flow from the central passage 106 to the sleeve port 126 via the annular
region 130, and
allow fluid flow from the sleeve port 126 to the central passage 106 via the
annular region. In
other words, the directional control valve device 152 is configured to prevent
the injection of
fluid into the reservoir through the annular region 130, and allow fluid to be
produced from the
reservoir through the annular region 130. It is thus appreciated that the
directional control
valve device 152 can enable operation of the valve assembly 100 as a
production-only valve
when the top sleeve 124 is in the production position. The flow control device
150 can further
include a screen 154 superposed with the sleeve port 126 to enable a screened
production of
fluid from the reservoir. The screen 154 can be adapted to prevent various
particulates and/or
debris from entering the valve assembly and potentially clogging up the
annular region 130 or
being produced to surface.
[132] Now referring to Figures 7 to 10, an implementation of the top sleeve
124 is illustrated.
The top sleeve 124 includes a sleeve mandrel 160 defining a sleeve passage 161
therethrough, a collet 162 coupled to an uphole end of the sleeve mandrel 160
and a sleeve
cap 164 coupled to a downhole end of the sleeve mandrel 160. In some
implementations, the
collet 162 and the sleeve cap 164 are secured to the sleeve mandrel 160 via
interference fit,
although other connection methods can be used. The collet 162 can include a
latching
mechanism 165 adapted to releasably engage valve housing 102 to assist in
retaining the top
26
Date Recue/Date Received 2022-09-28
sleeve 124 in position within the valve housing. For example, the outer wall
can be provided
with annular grooves 116 (seen in Figures 4A and 10, among others) along the
inner surface
thereof, and the latch mechanism 165 can include one or more protrusions 166
extending
outwardly from the collet 162 for engaging the annular grooves 116, thereby
latching the top
sleeve to the outer wall to resist displacement of the top sleeve 124 along
the valve housing.
The annular grooves 116 can be provided at predetermined locations along the
valve housing
102 such that engagement of the annular grooves by the latching mechanism 165
corresponds
to an operational configuration of the valve assembly 100.
[133] In some implementations, the latch mechanism 165 of the collet 162
includes resilient
members 168, each provided with one or more of the protrusions 166 and
configured to bias
the protrusions outwardly to engage the annular groove of the housing. The
resilient members
168 are further adapted to move radially inwardly (e.g., within the sleeve
passage 161) upon
an application of sufficient force, such as from a shifting tool, for example.
It is appreciated
that moving the resilient members 168 radially inwardly can disengage the
protrusions 166
from the annular groove, thereby enabling a generally unhindered movement of
the top sleeve
124 along the valve housing. The resilient members 168 can be distributed
about the sleeve
mandrel 160, thereby defining openings and gaps therebetween through which
fluid flowing
along the fluid flowpath (C) can travel to flow past the collet 162 and into
the central passage
106. Referring back to Figure 4C, it is noted that the collet 162 defines the
upholemost
component of the top sleeve 124 such that the interstices 135 are defined
between the top
sub 108, the outer wall 103 and the collet 162, although other configurations
are possible.
[134] As seen in Figures 7 to 10, the sleeve cap 164 can be provided with the
sleeve port
126 such that aligning the sleeve cap 164 with the housing port 112
correspondingly aligns
the sleeve port 126 with the housing port 112. The sleeve port 126 can include
a plurality of
elongate slots 128 provided around the sleeve cap 164 for enabling fluid
communication
between the annular region and the housing port (and thus also with the
reservoir). In some
implementations, the housing port 112 includes as many openings 114 as the
sleeve port 126
includes elongate slots 128. However, it is appreciated that other
configurations are possible,
for example, and as seen in Figures 2 and 7, the housing port 112 includes
less openings 114
than the sleeve port 126 includes elongate slots 128.
[135] In this implementation, the screen 154 is superposed with the sleeve
port 126, and
more specifically with the elongate slots 128. As seen in Figures 8 and 8A,
the screen 154
can include one or more circumferential openings 155 disposed beneath the
elongate slots
128 and through which fluid flows during production. The circumferential
openings 155 are
illustratively smaller than the elongate slots 128, and are therefore adapted
to prevent
27
Date Recue/Date Received 2022-09-28
particulates, such as various debris, from entering the annular region. In
some
implementations, the elongate slots 128 are defined within a thickness of the
sleeve cap 164
and opens on an outer surface of the sleeve cap 164. Therefore, each elongate
slot 128 can
include a bottom surface, with the circumferential openings 155 being defined
through and
spaced along at least a portion of the bottom surface.
[136] In some implementations, the circumferential openings are generally
perpendicular
relative to the elongate slots and, although not illustrated as such, are
dispersed along the
entirety of the bottom surface. The space between each circumferential opening
155 can have
generally the same width as the circumferential openings themselves, such that
about 50% of
the bottom surface of each elongate slot 128 corresponds to circumferential
openings 155,
and the other 50% corresponds to the solid bottom surface. However, it is
appreciated that
other configurations are possible, such as having wider circumferential
openings 155, thinner
circumferential openings 155, or circumferential openings of varying
dimensions throughout
the same elongate slot 128 or between different slots 128.
[137] With reference to Figures 9 and 10, in addition to Figures 7 to 8A, the
annular region
130 is illustratively defined between the sleeve mandrel 160 and the outer
wall 103. Therefore,
it is noted that the volume of the annular region 130 can be at least
partially dependent on the
thickness of the sleeve mandrel 160 and/or of the outer wall 103. For
instance, increasing the
thickness of the wall of the sleeve mandrel 160 impedes on either the volume
of the annular
region 130, the volume of the central passage 106, or both. Similarly,
increasing the thickness
of the outer wall 103 (e.g., without increasing the width of the wellbore)
reduces the volume of
the annular region 130. Therefore, in order to define an annular region 130
adapted to house
one or more components, such as the flow control device 150, the thickness of
at least one of
the outer wall 103 and sleeve mandrel 160 can be made thinner.
[138] Reducing the thickness of either one of these walls can include risks.
The outer wall
103 is sized and configured to withstand a pressure differential between an
internal pressure
(e.g., along the central passage 106) and an exterior pressure (e.g., a
reservoir pressure). It
should thus be noted that reducing the thickness of the outer wall 103 risks
collapsing the
valve assembly. In this implementation, the sleeve mandrel 160 is not
subjected to a pressure
differential since the annular region 130 remains in fluid communication, or
fluid-pressure
communication, with the central passage 106. In other words, the pressure
within the annular
region 130 (e.g., within the annular chamber 132) is substantially the same as
the pressure
along the central passage 106.
28
Date Recue/Date Received 2022-09-28
[139] Therefore, it is noted that enabling fluid flow into the annular region
(i.e., into the
annular chamber 132) prior to cementing the wellbore string can create a
pressure-balanced
system between the annular region 130 and the central passage 106. As such,
the thickness
of the sleeve mandrel 160 can be reduced to increase the volume of the annular
region 130
since the sleeve mandrel 160 is not subjected to a pressure differential.
[140] In some implementations, the sleeve mandrel 160 can include a ring
portion 170
extending into the annular region 130 and engaging the inner surface 105 of
the outer wall
103. The ring portion 170 can therefore be adapted to define a downhole
annular region 134
in fluid communication with the sleeve port 126, and an uphole annular region
136 in fluid
communication with the central passage 106. The ring portion 170 also
illustratively includes
one or more through channels 172 establishing fluid communication between the
uphole and
downhole annular regions 134, 136. A seal 140 can be provided between the ring
portion 170
and the outer wall 103 to confine fluid flow through the through channels 172.
[141] Referring back to Figure 6A, when the valve assembly is in the flow-
restricted
configuration, the top sleeve 124 is in the production position and defines
the fluid flowpath
(C) which includes the following path: i) production fluid flowing into the
valve assembly via
the housing port 112, ii) production fluid flowing into the downhole annular
region 134 via the
sleeve port 126 (e.g., through the elongate slots 128 and the screen 154),
iii) production fluid
flowing into the uphole annular region 136 via the through channels 172, and
iv) production
fluid flowing along the annular region, past the collet 162 and into the
central passage 106.
[142] Referring broadly to Figures 6 to 10, the directional control valve
device 152 can be
coupled to the sleeve mandrel 160 in the uphole annular region 136, and
configured to
selectively control fluid flow along the annular region 130, and more
specifically through the
through channels 172 of the ring portion 170. For example, in this
implementation, the
directional control valve device 152 comprises a displaceable member 180
provided within the
uphole annular region 136 and being movable between an engaged position (seen
in Figure
10), where the displaceable member 180 at least partially prevents fluid
communication
between the uphole and downhole annular regions 134, 136, and a disengaged
position (not
shown), where fluid communication between the uphole and downhole annular
regions is
allowed via the through channels 172. The directional control valve device 152
can further
include a biasing member 182 operatively coupled to the displaceable member
180 for biasing
the displaceable member 180 in the engaged position.
[143] In this implementation, the displaceable member 180 can be displaced
from the
engaged position to the disengaged position via fluid flow, such as fluid
flowing from the
29
Date Recue/Date Received 2022-09-28
reservoir into the annular region 130. More specifically, fluid flowing from
the reservoir into
the downhole annular region 134 can generate hydraulic pressure on the
displaceable
member 180, causing it to move into the disengaged position and enable fluid
flow through
the through channels 172. It is noted that fluid flow in the opposite
direction, i.e., toward the
reservoir is blocked as it does not displace the displaceable member 180.
[144] In some implementations, the directional control valve device 152
includes an axial
check valve device 184 configured to prevent axial flow from the uphole
annular region 136 to
the downhole annular region 134. The displaceable member 180 of the axial
check valve
device 184 can include a check valve head, such as a ring plug member 186,
engageable with
the ring portion 170 of the sleeve mandrel 160. Additionally, the biasing
member 182 of the
axial check valve device 184 can include a spring 188 operatively coupled
between the ring
plug member 186 and the collet 162 within the annular region 130 to bias the
ring plug member
186 in the engaged position. As seen in Figure 10, when in the engaged
position, the front
edge 187 of the ring plug member 186 sealingly engages the ring portion 170 to
prevent fluid
flow between the annular regions 134, 136 via the through channels 172. In
this
implementation, the ring plug member 186 is slidably mounted about the sleeve
mandrel 160
such that hydraulic pressure within the downhole annular region 134 can
generate a force on
the axial check valve device 184, thereby compressing the spring 188 and
moving the ring
plug member 186 away from the ring portion 170 to the disengaged position. It
should be
noted that when fluid flow is stopped, or reduced, the spring 188 is
configured to push the ring
plug member 186 back to the engaged position.
[145] Still with reference to Figures 9 and 10, the ring portion 170 includes
an outer surface
which engages the inner surface 105 of the outer wall 103. In this
implementation, the outer
surface of the ring portion 170 includes an overhang 174 axially extending
within the uphole
annular region 136. The front edge 187 of the ring plug member 186 can be
shaped and
adapted to come into contact with the overhang 174 and create a seal therewith
to prevent
fluid flow through the ring portion 170 via the through channels 172. The
front edge 187 is
illustratively tapered such that a portion thereof is shaped and sized to at
least partially extend
below the overhang 174, with the tapered surface sealingly engaging the
overhang 174 when
in the engaged position. The axial check valve device 184 can also be provided
with a seal
140 provided between the ring plug member 186 and the sleeve mandrel 160 such
that fluid
flow is prevented both above and below the ring plug member 186 when engaged
with the
ring portion 170. As seen in Figure 9, the front edge 187 can be substantially
continuous such
that the tapered surface of the front edge is correspondingly continuous and
uniformly
engages the overhang 174. However, it is appreciated that other configurations
are possible,
Date Recue/Date Received 2022-09-28
or example, the front edge 187 can include a plurality of plug members
configured to engage
and plug respective through channels 172 for preventing fluid flow
therethrough.
[146] Now referring to Figures 11 to 15, an alternate implementation of the
top sleeve 124 is
illustrated. The sleeve mandrel 160, collet 162 and sleeve cap 164 are
substantially the same
as those described above. However, in this implementation, the directional
control valve
device 152 includes a radial check valve device 190, where the displaceable
member 180 is
configured to move radially between the sleeve mandrel 160 and the outer wall
to selectively
control fluid flow between the downhole and uphole annular regions 134, 136.
In this
implementation, the displaceable member 180 includes a plurality of radial
poppets 192
provided about the ring portion 170 for obstructing respective through
channels 172, when in
the engaged position. Each radial poppet 192 can be configured to block one
end of one of
the through channels 172, such as the end adapted to communicate with the
uphole annular
region 136, for example.
[147] During production, fluid flows from the reservoir, through the housing
port, through the
sleeve port 126 and into the downhole annular region 134. The hydraulic
pressure increases
and generates an outward radial force on a bottom surface of the radial
poppets 192 to
disengage, or "unseat", the radial poppet 192 from its engaged and occluding
position. As
seen in Figure 14A, the radial poppet 192 can be provided with one or more
seals 140 for
preventing fluid flow when in the engaged, or "seated" position. Once
sufficient hydraulic
pressure is created below (e.g., within the through channels 172 and the
downhole annular
region 134), the radial poppet 192 is lifted from its seat, thereby enabling
fluid flow around the
radial poppet 192, into the uphole annular region 136 and finally in the
central passage 106.
Each radial poppet 192 can be configured to selectively block a single through
channel 172,
although other configurations are possible, such as providing a radial poppet
192 for more
than one through channel, for example. It should also be noted that, in some
implementations,
the directional control valve device 152 can include a combination of axial
and radial check
valve devices, or any other type of flow directional control device.
[148] With reference to Figures 16 to 26, alternate implementations of flow
control devices
150 are illustrated. For instance, with reference to Figure 16, an
implementation of an axial
poppet check valve 200 is shown. In this implementation, the poppet member 202
can be
provided in the annular region and functions in a similar way as the axial
check valve device
described above. Fig 16 shows the axial poppet member 202 in the open
position, or retracted
position, once fluid pressure forces the poppet away from the through channel
172. Fluid
communication is thus created to enable flow past and/or through the poppet
(e.g., via internal
channels 204 of the axial poppet member 202), along the annular region. Figure
16 shows an
31
Date Recue/Date Received 2022-09-28
axial poppet check valve preventing injection outflow and enabling production
inflow. An axial
poppet check valve could also be provided for another valve for preventing
production inflow
and enabling injection outflow by reorienting the poppet member and the
biasing member
within the annular region, such as the implementation shown in Figures 17 and
18, for
example. It is appreciated that the implementations the poppet check valve of
Figures 17 and
18 can be used in injection-only valves, where production is prevented at
predetermined
stages of the wellbore.
[149] Referring now to Figures 18 to 24, a reed type check valve can be used
wherein a reed
is incorporated with the sleeve in various ways.
[150] Referring to Figs 19-21, each reed check valve can include a reed petal
210 that is
attached at one end to the top sleeve 124 via an attachment 212 while enabling
the opposed
end to flex from a closed position to an open position in response to fluid
pressure from one
direction. Fig 19 shows the reed petal 210 fixed proximate the uphole end of
the sleeve and
arranged so that an end section of the reed petal 210 can rest on a support
portion of the
sleeve in the closed position and then flex or pivot in response to fluid
pressure from below to
move the reed petal to the open position to define an opening that allows
fluid communication
past the reed petal 210. In Fig 19, the reed petal 210 is arranged to flex
radially outward in
response to fluid pressure that flows from the exterior of the valve and
through the through
channels 172. A gap can be defined between the housing 103 and the support
portion to
enable the reed petal 210 to flex toward the housing inner surface to enable
fluid to pass
through. When the fluid pressure is on the inside of the valve, the reed petal
210 tends to
remain closed for the reed check valves of Fig 19, which can thus be used in a
production-
only valve. In addition, the sleeve 124 can be composed of two or more parts,
if desired, for
ease of manufacturing and assembly of the different portions of the various
features.
[151] Fig 20 shows a reed check valve for an injection-only scenario wherein
the reed petal
210 is arranged to flex radially outward in response to fluid pressure from
the interior of the
valve. Fluid can flow through the annular region to force the reed petal to
open and then flow
through the housing port 112 and into the reservoir.
[152] The reed check valves illustrated in Figs 19-20 are arranged so that the
reed petal 210
flexes radially and thus deflects from a closed position that can be generally
aligned with a
longitudinal axis of the sleeve to an open position at an angle, which may be
acute, with
respect to the longitudinal axis. This general configuration can be referred
to herein as a side-
bending configuration of the reed check valve. The side-bending reed valve can
be used for
injection or production in various valve implementations. The side-bending
reed valve can be
32
Date Recue/Date Received 2022-09-28
integrated within the sleeve of the valve, as shown in Figs 19-20, or with the
housing itself if
desired. As shown in Figs 19-20, the reed valve can be arranged so that the
reed petal bends
outward toward the open position, rather than bending inward toward the middle
of the valve.
Outward bending can reduce issues related to catching tools and the like that
can be run
through the sleeve. Orientations of the sleeve parts, the reed petal, and
related equipment
that reduce the risk of catching can be beneficial (e.g., reed petals that are
shielded from tool
deployment, as shown in Figs 19-20). In other terms, the reed petal 210 can be
oriented so
that it does not create an obstruction. The reed petal can also be arranged
facing either axial
direction (the loose end uphole or downhole) with the sleeve and channels
being arranged
accordingly.
[153] Turning to Figs 21-23, the reed check valve can be provided in an
alternative
arrangement that can be referred to as an end-bending configuration. In the
closed position,
the reed petal 210 can be oriented generally perpendicular to the longitudinal
axis of the
sleeve, and in response to fluid pressure the reed petal 210 flexes to an
angle to allow fluid
passage in one direction. In this implementation, the reed petal 210 can be
arranged to cover
an outlet of the through channels 172. As shown in Figs 22-23, each through
channel 172 can
be covered by a reed petal 210. A pair of adjacent through channels 172 can
also be covered
by a single reed petal 210 with first and second sides that cover respective
through channels
172 and the attachment 212 securing the reed petal 210 in between the adjacent
through
channels 172. The reed petal 210 could alternatively be secured to the end of
the sleeve in
other configurations so that the reed petal bends in one or various
directions. It is noted that
the end-bending configuration could also include an additional inner sleeve
part configured to
shield the reed petal.
[154] While Figs 19-20 show a side-bending configuration and Fig 21-23 show an
end-
bending configuration, it should be noted that other angle of the reed petal
and associated
through channels 172 are possible. In other words, the reed petal does not
have to be parallel
or perpendicular to the sleeve longitudinal axis, but can be oriented at other
angles.
[155] Referring to Fig 24, it is also noted that the reed check valve can be
provided in the
form of an angled reed valve device 220, where the reed petals 210 are
arranged at an angle
with respect to the longitudinal orientation in the closed position. For
example, the reed petals
can be mounted to a reed block 222 that includes a base plate 224, angled
walls 226 extending
from the base plate 224 and side walls (not shown) also extending from the
base plate, such
that the walls define a flow cavity 225. The base plate 224 defines a base
opening 228, and
the angled walls include openings 230 over which the reed petals 210 are
provided. The fluid
can flow through the base opening, into the cavity, and out of the openings,
deflecting the reed
33
Date Recue/Date Received 2022-09-28
petals 210 in one direction (i.e., from right to left in Fig 24); but the
fluid is prevented from
flowing in the opposite direction. Each reed petal 210 can also be overlaid
with a stop plate
232 that can be curved and configured to define the maximum open position of
the reed petal.
In this regard, is it noted that a dedicated stop plate component can be
provided for various
reed valves, or certain components of the valve (e.g., housing, sleeve, etc.)
can act as a stop
plate depending on the configuration of the reed petal.
[156] Referring back to Figure 1, the wellbore 10 includes a casing 11 lining
an inner surface
of the wellbore 10. The casing 11 can be adapted to contribute to the
stabilization of the
reservoir 14 after the wellbore 10 has been drilled, e.g., by contributing to
the prevention of
the collapse of the walls of the wellbore 10. In some implementations, the
casing 11 includes
one or more successively deployed concentric casing strings, each of which is
positioned
within the wellbore 10. In some implementations, each casing string includes a
plurality of
jointed segments of pipe. The jointed segments of pipe typically have threaded
connections
although other configurations are possible and may be used.
[157] It can be desirable to seal an annulus formed within the wellbore
between the casing
string 11 and the reservoir 14. Sealing of the annulus can be desirable for
preventing injection
fluid from flowing into remote zones of the reservoir, thereby providing
greater assurance that
the injected fluid is directed to the intended zones of the reservoir. To
prevent or at least
interfere with injecting fluid into an unintended zone of the reservoir, this
annulus can be filled
with an isolation material, such as cement, thereby cementing the casing to
the reservoir 14.
It should be noted that the cement can also provide one or more of the
following functions: (a)
strengthens and reinforces the structural integrity of the wellbore, (b)
prevents, or substantially
prevents, produced fluids of one zone from being diluted by water from other
zones, (c)
mitigates corrosion of the casing 11, and (d) at least contributes to the
support of the casing
11.
[158] It is further noted that the casing 11 can include a plurality of casing
outlets for allowing
fluid flow between the wellbore string 30 and the reservoir (e.g., via
injection and production
segments of the valve assembly 100). In some implementations, in order to
facilitate fluid
communication between the wellbore string 30 and the reservoir 14, each of the
casing outlets
can be substantially aligned with, or at least proximate to, a housing port of
the valve assembly
100. In this respect, in implementations where the wellbore 10 includes the
casing 11, injection
fluid is injected from the surface down the wellbore string 30 in order to
reach the valve
assembly 100. Injection fluid then flows through the open housing port of the
corresponding
34
Date Recue/Date Received 2022-09-28
valve assemblies and into an annular space defined between certain portions of
the wellbore
string 30 and the casing string 11, and finally into the reservoir 14 via the
casing outlets.
[159] In another possible implementation, and with reference to Figures 25 and
26, the valve
assembly can be provided with a single sleeve, such as the top sleeve 124,
shiftable between
various positions and being adapted to close the housing port 112, open the
housing port 112
and/or restrict the housing port 112. In other words, the different
configurations of the valve
assembly described herein can be generally replicated using only one valve
sleeve (i.e.,
instead of the dual-sleeve assembly described above). Referring more
specifically to Figure
25, the top sleeve 124 can include an occluding portion 240 adapted to be
aligned with the
housing port 112 to operate the valve assembly 100 in the closed
configuration. The occluding
portion 240 can correspond to a portion of the sleeve cap 164 which is
illustratively provided
with one or more seals 140 between the outer wall and the occluding portion
240 (e.g., the
sleeve cap 164) to prevent fluid communication between the reservoir and the
central passage
106.
[160] The top sleeve 124 can be shifted between the closed position (shown)
and a screened
position, where the screen 154 is aligned with the housing port 112, as
described above.
Similar to previously described implementations, the screen 154 can be
provided on the sleeve
cap 164, such that shifting the top sleeve 124, for example in the downhole
direction, displaces
the occluding portion 240 to no longer block the housing port 112, and moves
the screen 154
in alignment with the housing port 112. In this implementation, the outer wall
103 includes a
pair of annular grooves 116 where the collet 162 is adapted to engage via the
latching
mechanism 165. The annular grooves are provided at predetermined locations
such that
engagement of a first annular groove, such as the upholemost annular groove
116a
corresponds to positioning the top sleeve in the closed position (e.g., with
the occluding portion
240 aligned with the housing port 112), and engagement of a second annular
groove, such as
the downholemost annular groove 116b corresponds to positioning the top sleeve
in the
screened position.
[161] With reference to Figure 26, another implementation of the valve
assembly 100 is
shown. In this implementation, the top sleeve 124 includes generally the same
structure as
the implementation of Figure 25. However, the valve housing 102 is shaped and
adapted to
enable movement of the top sleeve in both the uphole and the downhole
directions. As such,
it is appreciated that the top sleeve can be displaced into three different
operational positions.
As seen in Figure 26, the valve housing includes three (3) annular grooves
116, including the
upholemost annular groove 116a, the downholemost annular groove 116b, and a
central
Date Recue/Date Received 2022-09-28
annular groove 116c therebetween, although additional annular grooves can be
provided. The
top sleeve 124 can thus be displaced along the valve housing to enable
engagement of the
latching mechanism 165 in any one of the three (3) annular grooves 116, which
corresponds
to operation of the valve assembly in three operational configurations (e.g.,
three different
operational configurations).
[162] For example, the valve assembly can be run downhole with the top sleeve
in the run-
in position, with the latching mechanism 165 engaging the central annular
groove 116c, which
corresponds to the closed position in this implementation. In other words, the
valve assembly
100 is run downhole with the occluding portion 240 of the top sleeve aligned
with the housing
port 112. Once in place, the top sleeve can be either shifted downhole or
uphole, for
engagement of the latching mechanism with one of the other annular grooves
116a, 116b. In
this implementation, shifting the top sleeve downhole aligns the screen 154
with the housing
port 112, thus operating the valve assembly in the screened configuration.
Moreover, shifting
the top sleeve uphole opens the housing port 112 to direct fluid communication
with the central
passage, thus operating the valve assembly in the open configuration (e.g.,
for fracturing
purposes, for injection into the reservoir or for unrestricted production of
reservoir fluids).
[163] It should be noted that the structural components of the top sleeve can
be "flipped"
along the valve housing such that shifting the top sleeve uphole moves the top
sleeve to the
screened position, and shifting the top sleeve downhole moves the top sleeve
to the open
position, for example. In addition, although Figures 25 and 26 illustrate the
top sleeve with the
axial check valve device configured to operate the valve assembly in a
production-only valve,
it should be noted that any other suitable type or combination of flow control
devices can be
used, such as flow control devices configured to operate the valve assembly in
an injection-
only valve, for example.
[164] Now referring to Figures 27 to 29, another implementation of the valve
assembly is
illustrated. In this implementation, the valve assembly 100 includes a dual-
sleeve assembly
(e.g., a bottom sleeve 122 and a top sleeve 124) and further includes a flow-
controlling sleeve
250 coupled to one of the bottom sleeve 122 and the top sleeve 124, such as to
the top sleeve
124. In some implementations, the flow-controlling sleeve 250 includes the
flow control device,
or a portion thereof, and includes a flow-controlling sleeve mandrel 252
provided between the
top sleeve 124 and the outer wall 103 of the housing. As will be described
further below, the
flow-controlling sleeve 250 can be slidably mounted within the valve housing,
such as slidably
mounted between the top sleeve 124 and the outer wall 103, for example, which
enables
movement of the flow-controlling sleeve 250 along the valve housing relative
to the outer wall
103 and/or the top and bottom sleeves. It is thus noted that the flow-
controlling sleeve 250
36
Date Recue/Date Received 2022-09-28
can be at least partially mounted within the annular region 130, such as
within the annular
chamber 132.
[165] In Figures 27 and 27A, the valve assembly 100 is operated in the closed
configuration,
where the bottom sleeve 122 occludes the housing port 112 to prevent fluid
communication
between the central passage 106 and the reservoir. In a similar fashion to
previously described
implementations, the bottom sleeve can be shifted (e.g., in the downhole
direction) to an open
position (seen in Figure 28) and enable operation of the valve assembly in the
open
configuration. It is appreciated that the open configuration of the valve
assembly 100 enables
fracturing of the reservoir, injection into the reservoir via the housing port
and/or unrestricted
production of reservoir fluids through the housing port into the central
passage 106.
[166] In this implementation, the top sleeve 124 is provided with an annular
inlet 252 adapted
to establish fluid communication between the central passage and the annular
region 130 such
that wellbore fluid within the central passage can flow within the annular
region. As previously
described, this initial ingress of fluid can pressurize the annular chamber
132 and prevent
subsequent fluids or material (e.g., cement) from flowing into the chamber. In
this
implementation, the annular inlet 252 includes a plurality of slotted inlets
circumferentially
dispersed along an inner surface of the top sleeve. Therefore, fluid flowing
along the central
passage can go through the slotted inlets and into the annular region 130.
With the flow-
controlling sleeve 250 positioned within the annular chamber, it is
appreciated that the flow-
controlling sleeve 250 can be protected from cement due to the previous fluid
pressurization
of the annular chamber.
[167] In some implementations, once the reservoir has been fractured, the
bottom sleeve
can be shifted back uphole to the closed position to prevent back flow of the
fracturing fluid
from the formation and allow "healing" or equilibration of the reservoir prior
to production.
Alternatively, and with reference to Figure 29, the top sleeve 124 can be
shifted downhole to
overlay and at least partially block the housing port 112. In this
implementation, the flow-
controlling sleeve 250 can include a sleeve shoulder 256 at a downhole end
thereof against
which the top sleeve can abut. The sleeve shoulder 256 is defined by a portion
of the flow-
controlling sleeve 250 which has a smaller inner diameter, thereby enabling
the top sleeve to
abut thereon. It should thus be understood that shifting the top sleeve in the
downhole direction
pushes against the sleeve shoulder 256 and correspondingly displaces the flow-
controlling
sleeve 250 along with the top sleeve.
[168] As seen in Figure 29, the valve assembly can be operated in a secondary
closed
configuration by shifting down the top sleeve, which displaces the flow-
controlling sleeve 250
37
Date Recue/Date Received 2022-09-28
for alignment thereof with the housing port 112. It is thus noted that, in
this implementation,
the downhole end of at least one of the top sleeve and the flow-controlling
sleeve 250 can be
of an occluding nature (e.g., not slotted or provided with openings) to
prevent fluid
communication between the reservoir and the central passage 106. In some
implementations,
the flow-controlling sleeve 250 is provided with the latching mechanism 165,
such as the
latching mechanism previous described in relation to the collet, configured to
releasably
engage the outer wall 103 for positioning and retaining the flow-controlling
sleeve 250 at
predetermined locations within the valve housing. In some implementations,
shifting the top
sleeve and the flow-controlling sleeve 250 downhole brings the flow-
controlling sleeve 250 in
abutment with the bottom sleeve 122 to prevent further downhole movement,
although other
configurations are possible.
[169] Referring now to Figure 30, in this implementation, the downhole end of
the flow-
controlling sleeve 250 is provided with the flow control device, and more
specifically, the
downhole end includes the screen 154. In some implementations, the screen 154
can define
a slotted region of the flow-controlling sleeve 250, whereby the flow-
controlling sleeve 250 is
provided with a plurality of openings 155 defined through a thickness of the
flow-controlling
sleeve mandrel 252. As seen in Figure 30, the openings 155 can be
substantially parallel to
one another and the longitudinal axis of the valve assembly. The openings 155
can have any
suitable shape, size and/or configuration, although it is appreciated that
wider and/or a greater
number of openings 155 can allow a greater flowrate of fluid into the valve
assembly.
[170] Still with reference to Figure 30, the valve assembly 100 can be
operated in a screened
configuration, where the screen 154 is aligned with the housing port 112 for
enabling a
screened production of reservoir fluids. In this implementation, to operate
the valve assembly
from the secondary closed configuration (seen in Figure 29) to the screened
configuration
(seen in Figure 30), the top sleeve is shifted back uphole, such as back to
its initial run-in
position. With the flow-controlling sleeve 250 being slidable relative to the
top sleeve and
coupled to the outer wall via the latching mechanism, the top sleeve can be
shifted back uphole
by itself (i.e., without dragging the flow-controlling sleeve 250 back with
it). As such, the screen
154 remains aligned with the housing port 112 for operation of the valve
assembly in the
screened configuration.
[171] In this implementation, the flow-controlling sleeve 250 can be reverted
to its initial
isolated position within the annular region. For example, from the secondary
closed or
screened configuration, the bottom sleeve 122 can be shifted in the uphole
direction. The
bottom sleeve can abut the flow-controlling sleeve 250 and can therefore push
the flow-
controlling sleeve 250 in the uphole direction. When in the secondary closed
configuration
38
Date Recue/Date Received 2022-09-28
(Figure 29), the sleeve shoulder 256 abuts and pushes on the top sleeve, such
that all three
(3) sleeves are shifted uphole when shifting the bottom sleeve in the uphole
direction. When
in the screened configuration (Figure 30), it is noted that the top sleeve is
already in its initial
uphole position such that the flow-controlling sleeve 250 can be pushed into
the annular region
130 between the top sleeve and the outer wall 103. It should thus be
understood that the valve
assembly can be operated from the closed configuration to the open
configuration, to the
secondary closed configuration, to the screened configuration and back to the
closed
configuration. In other words, the valve assembly can be operated back in any
one of the
operational configurations for performing any corresponding wellbore
operation. For example,
the valve assembly can be reverted back into the open configuration (e.g.,
after having
produced reservoir fluid through the screen) to enable fracturing the
reservoir a subsequent
time.
[172] Now referring to Figures 31 to 35A, another implementation of the valve
assembly is
illustrated. In this implementation, the valve assembly 100 includes a dual-
sleeve assembly
(e.g., a bottom sleeve 122 and a top sleeve 124) and further includes a flow-
controlling sleeve
250 coupled to one of the bottom sleeve 122 and the top sleeve 124, such as to
the bottom
sleeve 124. In some implementations, the flow-controlling sleeve 250 includes
the flow control
device, or at least a portion thereof. As will be described further below, the
flow-controlling
sleeve 250 can be slidably mounted within the valve housing which enables
movement of the
flow-controlling sleeve 250 along the valve housing as the valve sleeves are
displaced.
[173] In Figures 31 and 31A, the valve assembly 100 is operated in the closed
configuration,
where the bottom sleeve 122 occludes the housing port 112 to prevent fluid
communication
between the central passage 106 and the reservoir. While the valve sleeves
122, 124 are in
the closed position, the flow-controlling sleeve 250 is illustratively
positioned between a
downhole end of the top sleeve 124 and the outer wall 103. It is thus noted
that the flow-
controlling sleeve 250 can be at least partially mounted within the annular
region 130, such as
within the annular chamber 132. In a similar fashion to previously described
implementations,
the bottom sleeve can be shifted (e.g., in the downhole direction) to an open
position (seen in
Figures 32 and 32A) and enable operation of the valve assembly in the open
configuration. It
is appreciated that the open configuration of the valve assembly 100 enables
fracturing of the
reservoir, injection into the reservoir via the housing port and/or
unrestricted production of
reservoir fluids through the housing port into the central passage 106.
[174] In this implementation, the top sleeve 124 is provided with an annular
inlet, or a vent
252, adapted to establish fluid communication between the central passage and
the annular
region 130 such that wellbore fluid within the central passage can flow within
the annular
39
Date Recue/Date Received 2022-09-28
region. As previously described, this initial ingress of fluid can pressurize
the annular chamber
132 and prevent subsequent fluids or material (e.g., cement) from flowing into
the chamber.
In this implementation, the annular inlet 252 includes one or more openings
circumferentially
dispersed along an inner surface of the top sleeve. Therefore, fluid flowing
along the central
passage can go through the openings and into the annular region 130. With the
flow-
controlling sleeve 250 positioned within the annular chamber, it is
appreciated that the flow-
controlling sleeve 250 can be protected from cement due to the previous fluid
pressurization
of the annular chamber.
[175] In some implementations, and as seen in Figure 33, once the reservoir
has been
fractured, the top sleeve 124 can be shifted toward the bottom sleeve (e.g.,
downhole) to a
secondary closed position occluding the housing port 112 in order to prevent
back flow of the
fracturing fluid from the formation and allow "healing" or equilibration of
the reservoir prior to
production. In this implementation, the top sleeve can be provided with a
latching mechanism
265 adapted to releasably latch onto the flow-controlling sleeve 250 when
moved in the
secondary closed position. Once the top sleeve is latched onto the flow-
controlling sleeve 250
via the latching mechanism 265, the top sleeve can be moved back uphole,
thereby dragging
the flow-controlling sleeve 250 and the bottom sleeve along with it. The flow-
controlling sleeve
250 is moved in this manner until the flow control device is aligned with the
housing port 112
to control fluid flow therethrough.
[176] In this implementation, the valve assembly 100 can be provided with a
lock ring 270
installed about the bottom sleeve and being adapted to at least partially
limit movement of the
bottom sleeve along the valve housing. As will be described further below, the
lock ring 270 is
configured to be inwardly biased such that the lock ring "squeezes" the bottom
mandrel. More
particularly, in this implementation, the bottom sleeve 122 includes a
downhole end adapted
to abut against an inner shoulder 274 of the valve housing to limit downhole
movement thereof.
It is noted that the bottom sleeve 122 can be in the open position when it
abuts the inner
shoulder 274.
[177] In addition, and with reference to Figures 34 to 35A, the mandrel of the
bottom sleeve
122 (i.e., the bottom mandrel) is adapted to slidably engage (e.g., contact)
the inner surface
of the valve housing along a portion of its length. The bottom mandrel can
have an inset region
276 defined along a portion thereof and having a smaller outer diameter,
thereby defining a
sleeve shoulder 278. In this implementation, moving the bottom sleeve in the
open position
(Figure 32) aligns the inset region with the lock ring 270, thereby enabling
the lock ring to
engage (e.g., "snap") onto the bottom mandrel along the inset region, but
remains partially
retained within an annular housing defined in the tubular wall 103. As such,
moving the flow-
Date Recue/Date Received 2022-09-28
controlling sleeve 250 and the bottom sleeve in the uphole direction is
limited by the lock ring
270, which abuts against the tubular wall 103 and the sleeve shoulder 278.
[178] In this implementation, the flow-controlling sleeve 250 includes the
screen 154, similar
to the implementation of Figures 27 to 30 such that fluid flow is restricted
through a slotted
region of the flow-controlling sleeve 250. However, it is appreciated that
other configurations
are possible. The valve assembly 100 can be operated in a screened
configuration, where the
screen 154 is aligned with the housing port 112 for enabling a screened
production of reservoir
fluids. In this implementation, to operate the valve assembly in the screened
configuration
(seen in Figure 35A), the top sleeve is shifted back uphole, thereby dragging
the flow-
controlling sleeve 250 and the bottom sleeve along with it via the latching
mechanism 265.
The lock ring 270, which is engaged with the inset region, abuts against the
sleeve shoulder
to limit uphole movement of the bottom sleeve and the flow-controlling sleeve.
The latching
mechanism 265 therefore releases the flow-controlling sleeve 250 (e.g., as the
top sleeve is
pulled further uphole), leaving the screen in position over the housing port
112, as seen in
Figure 35A.
[179] The latching mechanism 265 can include one or more components of the top
sleeve
124 configured to cooperate with the flow-controlling sleeve 250 or the bottom
sleeve 122 to
releasably couple these components together. For example, the bottom end of
the top sleeve
can be shaped, sized and/or adapted to engage the flow-controlling sleeve 250
in a releasable
press-fit connection. As such, the top sleeve can be shifted uphole and drag
the flow-
controlling sleeve 250 and the bottom sleeve until the lock ring blocks the
movement of the
bottom sleeve. Alternatively, or additionally, the top sleeve can be adapted
to engage oen or
more sealing elements 266, such as polymeric seals, provided about an inner
surface of the
flow-controlling sleeve 250. The sealing elements being adapted to provide
sufficient friction
between the flow-controlling sleeve 250 and the top sleeve to enable both
components to be
moved together. It is appreciated that other configurations or implementations
of the latching
mechanism 265 are possible and may be used.
[180] In this implementation, the top and bottom sleeves can be moved back and
forth
between the different operational positions described above. It should thus be
understood that
the valve assembly can be operated between the closed configuration, the open
configuration,
to the secondary closed configuration and the screened configuration, as
desired and/or
required.
[181] Now referring to Figures 36 to 38A, another implementation of the valve
assembly is
illustrated. In this implementation, the top sleeve 124 can be fixed (e.g.,
secured, immobile,
41
Date Recue/Date Received 2022-09-28
etc.) relative to the housing, and the bottom sleeve can include the flow
control device (e.g.,
the screen 154) provided at an uphole end thereof. In this implementation the
flow control
device is integrated with the mandrel of the bottom sleeve such that it forms
a single piece. As
seen in Figure 36 and 36A, the valve assembly 100 is operated in the closed
configuration,
where the bottom sleeve 122 occludes the housing port 112 to prevent fluid
communication
between the central passage 106 and the reservoir. While in the closed
position, the screen
is illustratively positioned between the top sleeve 124 and the outer wall
103. It is thus noted
that the screen 154 can be positioned within the annular region 130, such as
within the annular
chamber 132 for protection thereof. In a similar fashion to previously
described
implementations, the bottom sleeve can be shifted (e.g., in the downhole
direction) to an open
position (seen in Figures 37 and 37A) and enable operation of the valve
assembly in the open
configuration.
[182] In this implementation, the top sleeve 124 is provided with an annular
inlet, or vent 252,
adapted to establish fluid communication between the central passage and the
annular region
130 such that wellbore fluid within the central passage can flow within the
annular region. As
previously described, this initial ingress of fluid can pressurize the annular
chamber 132 and
prevent subsequent fluids or material (e.g., cement) from flowing into the
chamber. In this
implementation, fluid flowing along the central passage can go through the
annular inlet and
into the annular region 130.
[183] In this implementation, the valve assembly 100 is provided with a lock
ring 270 similar
to the previously described implementation. More specifically, the lock ring
270 is configured
to snap into an inset region of the bottom sleeve to limit uphole movement of
the bottom sleeve
as the lock ring abuts against the sleeve shoulder. When the lock ring 270
abuts the sleeve
shoulder 278, the screen 154 is positioned in alignment with the housing port
112 such that
fluid flow is controlled, restricted, filtered, etc., through the screen 154.
In other words, when
the lock ring 270 engages the sleeve shoulder, the valve assembly is operated
in the screened
configuration for enabling a screened production of reservoir fluids. In this
implementation, the
bottom sleeve can be moved back and forth between the different operational
positions
described above, with the top sleeve being fixed and secured to the valve
housing. It should
thus be understood that the valve assembly can be operated between the closed
configuration, the open configuration and the screened configuration, as
desired and/or
required.
[184] Now referring to Figures 39 to 45A, another implementation of the valve
assembly is
illustrated. In this implementation, the top sleeve 124 can be fixed (e.g.,
secured, immobile,
etc.) relative to the housing, and the bottom sleeve can include the flow
control device (e.g.,
42
Date Recue/Date Received 2022-09-28
the screen 154) provided at an uphole end thereof. As seen in Figure 40 and
40A, the valve
assembly 100 is operated in the closed configuration, where the bottom sleeve
122 occludes
the housing port 112 to prevent fluid communication between the central
passage 106 and the
reservoir. While in the closed position, the screen 154 is illustratively
positioned between the
top sleeve 124 and the outer wall 103. It is thus noted that the screen 154
can be positioned
within the annular region 130, such as within the annular chamber 132 for
protection thereof.
In a similar fashion to previously described implementations, the top sleeve
124 is provided
with an annular inlet, or vent 252, adapted to establish fluid communication
between the
central passage and the annular region 130 such that wellbore fluid within the
central passage
can flow within the annular region. As previously described, this initial
ingress of fluid can
pressurize the annular chamber 132 and prevent subsequent fluids or material
(e.g., cement)
from flowing into the chamber. In this implementation, fluid flowing along the
central passage
can go through the annular inlet and into the annular region 130.
[185] In this implementation, the bottom sleeve can be shifted (e.g., in the
downhole
direction) to an open position (seen in Figures 41 and 41A) and enable
operation of the valve
assembly in the open configuration, and can subsequently be shifted back
(e.g., in the uphole
direction) to align the screen 154 with the housing port 112 (seen in Figures
42 and 42A) and
enable operation of the valve assembly in the screened configuration. As will
be described
further below, the bottom sleeve 122 is adapted to move axially and radially
(e.g., rotate about
its longitudinal axis) within the valve housing when moving between the open,
closed and
screened positions.
[186] As seen in Figures 39, 41, 43 and 45, the bottom sleeve 122 can include
a guiding
track 280 defined along an outer surface thereof, and the valve housing can
include one or
more guiding pins 282 configured to engage the guiding track 280. As will be
understood, the
bottom sleeve is actuatable to move back and forth along the central passage
and the guiding
pins 282 remain generally stationary to limit movement of the bottom sleeve in
either
directions. For example, the guiding track 280 can include an elongated slot
285 extending
longitudinally along the bottom sleeve 122 having opposite ends defining stops
against which
the guiding pin 282 can abut, thereby limiting movement of the bottom sleeve
122 in the
corresponding direction. In other words, moving the bottom sleeve in the
closed position can
cause the guiding pin to engage a downhole end of the elongated slot, and
moving the bottom
sleeve in the open position can cause the guiding pin to engage an uphole end
of the
elongated slot.
[187] In this implementation, the guiding track 280 includes a plurality of
elongated slots 285,
dispersed radially about the bottom sleeve and extending substantially
parallel to one another.
43
Date Recue/Date Received 2022-09-28
The elongated slots 285 can include slots of varying lengths such that the
bottom sleeve can
be positioned at different locations along the central passage. As will be
described below, the
guiding track 280 can include angled surfaces 290 configured to offset the
position of the
guiding pin relative to the elongated slots as it slides along the angled
surfaces. It is thus noted
that the angled surfaces 290 can be adapted to rotate the bottom sleeve within
the central
passage as the bottom sleeve is moved to engage the angled surfaces with the
guiding pin.
As such, the guiding pin 282 can be made to engage different elongated slots
285 around the
bottom sleeve to limit movement of the bottom sleeve in a given direction to
position the screen
in various, selected and/or desired locations. In this implementation, the
bottom sleeve can
have a symmetrical configuration, with a pair of guiding pins 282 engaging
respective
elongated slots on either side of the bottom sleeve, although other
configurations are possible
(e.g., a single guiding pin, three or more guiding pins, asymmetrical
configuration, etc.).
[188] Still referring to Figures 39, 41, 43 and 45, the guiding track 280
includes first slots 286
having a first length, and second slots 288 having a second length. The first
length can be
greater than the second length such that engaging the guiding pins within the
first slots to
contact the downhole end thereof can position the bottom sleeve in the closed
position (e.g.,
in the upholemost position of the bottom sleeve), as seen in Figures 41 and
41A. It is thus
noted that engaging the guiding pins within the second slots, as seen in
Figures 45 and 45A,
can position the bottom sleeve in the screened position, where the screen is
aligned with the
housing port, as seen in Figures 44 and 44A. In this implementation, the first
and second slots
alternate each other around the bottom sleeve. However, it is appreciated that
other
configurations are possible.
[189] In this implementation, the angled surfaces 290 include a first set of
angled surfaces
290a adapted to rotate the bottom sleeve when moving in the downhole
direction, and a
second set of angled surfaces 290b adapted to rotate the bottom sleeve when
moving in the
uphole direction. The first and second sets of angled surfaces extend in
generally opposite
directions such that moving the bottom sleeve back and forth (e.g.,
alternating downhole and
uphole movements) rotates the bottom sleeve within the central passage in the
same direction.
As seen in Figure 43 and 43A, moving the bottom sleeve downhole causes the
angled
surfaces of the first set 290a to engage the guiding pins until the pin is
positioned in a corner
of the guiding track. The bottom sleeve is thus rotated to position the
guiding pin between an
adjacent pair of elongated slots (seen in Figure 43). Then, the bottom sleeve
can be shifted
uphole, thereby engaging the angled surfaces of the second set with the
guiding pins, which
further rotates the bottom sleeve to align the guiding pins with an elongated
slot (seen in Figure
45).
44
Date Recue/Date Received 2022-09-28
[190] Now referring to Figures 46 to 48A, another implementation of the valve
assembly is
illustrated. In this implementation, the valve assembly 100 includes a dual-
sleeve assembly
(e.g., a bottom sleeve 122 and a top sleeve 124) and further includes the flow-
controlling
sleeve 250 coupled to the top sleeve 124. The flow-controlling sleeve 250
includes the screen
154, which is installed between the top sleeve 124 and the outer wall 103 of
the housing. It is
thus noted that the screen 154 is at least partially mounted within the
annular region 130, such
as within the annular chamber 132 for protection thereof. The annular chamber
can be in fluid
communication with the central passage via interstices 135 defined between the
top sleeve
and the housing. The interstices are adapted to establish fluid communication
between the
central passage and the annular region 130 such that wellbore fluid within the
central passage
can flow within the annular region. Alternatively, the top sleeve can include
vents configured
to allow an ingress of fluid within the annular chamber. As previously
described, this initial
ingress of fluid can pressurize the annular chamber 132 and prevent subsequent
fluids or
material (e.g., cement) from flowing into the chamber.
[191] In Figures 46 and 46A, the valve assembly 100 is operated in the closed
configuration,
where the bottom sleeve 122 occludes the housing port 112 to prevent fluid
communication
between the central passage 106 and the reservoir. In a similar fashion to
previously described
implementations, the bottom sleeve can be shifted (e.g., in the downhole
direction) to an open
position (seen in Figure 47) and enable operation of the valve assembly in the
open
configuration. Then, the top sleeve can be shifted downhole to operate the
valve assembly in
the screened configuration, where the screen 154 is aligned with the housing
port 112 for
enabling a screened production of reservoir fluids.
[192] Similar to the implementation of Figure 6A, the top sleeve 124 can be
shaped and
configured to sealingly engage the housing 102 at the downhole end thereof. As
such, fluid
flowing through the housing port 112 is substantially confined to flow through
the annular
chamber 132 and past the uphole end of the top sleeve 124 to reach the central
passage 106.
In this implementation, the flow control device further includes an ICD 300
(inflow control
device) coupled about the top sleeve proximate the uphole end thereof. The ICD
300 can
include a ring 302 disposed between the top sleeve and the housing and
configured to restrict
fluid flow therethrough. For example, the ring 302 can include a plurality of
axial passages 304
extending therethrough. The top sleeve can be releasably connected to the
housing via a
latching mechanism (e.g., a collet 305) configured to engage annular grooves
defined in the
housing. In some implementations, the top sleeve further includes a collet
shroud 310 installed
in the annular region and configured to at least partially protect the collet
305 as production
fluid flows along the annular chamber, for example.
Date Recue/Date Received 2022-09-28
[193] The implementation of the valve assembly illustrated in Figures 49 to
51A is similar to
the implementation of Figures 46 to 48A described above. From the closed
configuration
(Figures 49 and 49A), the bottom sleeve 124 is shifted downhole to operate the
valve
assembly in the open configuration (Figures 50 and 50A). Then, the top sleeve
can be shifted
downhole to align the screen 154, which is installed in the annular chamber,
with the housing
port 112. In this implementation, the uphole end of the top sleeve sealingly
engages the tubular
wall 103 such that production fluids are urged through the housing port 112,
through the
screen 154, along the annular chamber 132 and through the vents 252 to flow
into the central
passage 106. An ICD 300 can be installed along the annular region 130, such as
within the
annular chamber, such as between the screen 154 and the vents 252, for
example.
[194] With reference to Figures 52 to 55A, another implementation of the valve
assembly
100 is shown. In this implementation, the screen 154 is coupled to the top
sleeve 124 and
installed within the annular chamber 132. Figures 52 and 52A illustrate the
valve assembly in
the closed configuration. From there, the bottom sleeve 122 can be shifted
downhole to open
the housing port 112, thereby operating the valve assembly in the open
configuration, as seen
in Figures 53 and 53A. Then, the top sleeve can be shifted downhole to align
the screen 154
with the housing port 112 (Figures 54 and 54A), and subsequently shifted back
uphole, leaving
the screen 154 in alignment with the housing port to operate the valve
assembly in the
screened configuration (Figures 55 and 55A). It is noted that, in this
implementation, the
screen 154 includes a plurality of radial openings. However, the screen can be
provided with
longitudinal slots (as described in relation with previous implementations), a
combination of
radial openings and longitudinal slots, or any other suitable
configuration(s).
[195] In this implementation, the top sleeve 124 includes a top sleeve latch
320 (e.g., a top
sleeve collet) configured to releasingly engage the tubular wall 103 at
predetermined locations.
As such, the top sleeve can be coupled to the tubular wall in the run-in
position (Figures 52,
53 and 55) and in the shifted position (Figure 54). In addition, the screen
154 can be provided
with a screen latch 325 (e.g., a screen collet) configured to releasingly
engage the tubular wall
103 at predetermined locations. As such, the screen can be coupled to the
tubular wall in the
run-in position (Figures 52 and 53), and in an aligned position (Figures 54
and 55). The top
sleeve can include a shoulder adapted to engage and push the screen when
moving
downhole. Therefore, shifting the top sleeve from the run-in position to the
shifted position
simultaneously moves the screen from the run-in position to the aligned
position. However,
the top sleeve is adapted to disengage the screen when moving uphole such that
the top
sleeve can be shifted back to the run-in position while leaving the screen in
the aligned
position.
46
Date Recue/Date Received 2022-09-28
[196] With reference to Figures 56 to 60, another implementation of the valve
assembly 100
is shown. In this implementation, the screen 154 is coupled to the top sleeve
124 and installed
within the annular chamber 132. Figures 56 and 56A illustrate the valve
assembly in the closed
configuration. From there, the bottom sleeve 122 can be shifted downhole to
open the housing
port 112, thereby operating the valve assembly in the open configuration, as
seen in Figures
57 and 57A. Then, the top sleeve can be shifted downhole to align the screen
154 with the
housing port 112 (Figures 58 and 58A) to operate the valve assembly in the
flow-restricted
configuration, and subsequently shifted back uphole, leaving the screen 154 in
alignment with
the housing port to operate the valve assembly in the screened configuration
(Figures 59 and
59A). It should be noted that, in the flow-restricted configuration,
production fluids are
constrained or limited to flowing along the annular region prior to flowing
into the central
passage, whereas in the screened configuration, production fluids can flow
from the reservoir
to the central passage almost directly.
[197] In this implementation, the top sleeve 124 includes a top sleeve latch
320 (e.g., a top
sleeve collet) configured to releasingly engage the tubular wall 103 at
predetermined locations.
As such, the top sleeve can be coupled to the tubular wall in the run-in
position (Figures 56,
57 and 59) and in the shifted position (Figure 58). In addition, the screen
154 can be provided
with a screen latch 325 (e.g., a screen collet) configured to releasingly
engage the tubular wall
103 at predetermined locations. As such, the screen can be coupled to the
tubular wall in the
run-in position (Figures 56 and 57), and in an aligned position (Figures 58
and 59). The top
sleeve can include a shoulder adapted to engage and push the screen when
moving
downhole. Therefore, shifting the top sleeve from the run-in position to the
shifted position
simultaneously moves the screen from the run-on position to the aligned
position. However,
the top sleeve is adapted to disengage the screen when moving uphole such that
the top
sleeve can be shifted back to the run-in position while leaving the screen in
the aligned
position.
[198] Moreover, the valve assembly 100 can include a flow regulator 350
provided along the
annular region 130 adapted to at least partially control the fluid flowrate
through the annular
region when operating the valve assembly in the flow-restricted configuration.
As seen in
Figure 60, the flow regulator 350 can be defined along the outer surface of
the top sleeve and
can include a plurality of grooves 352 cooperating with one another to
restrict fluid flow through
the regulator. In this implementation, the flow regulator 350 forms part of
the top sleeve (e.g.,
the grooves are machined into a thickness of the top sleeve) and sealingly
engages the inner
surface of the valve housing. As such, the tubular wall of the housing
overlays the grooves,
restricting fluid flow along the various groove configurations. In this
implementation, the
47
Date Recue/Date Received 2022-09-28
grooves 352 include a combination of axial grooves and arcuate grooves adapted
to regulate
and/or restrict fluid flow from one side of the flow regulator to the other.
[199] Now referring to Figures 61 to 64A, this implementation of the valve
assembly 100
operates in a similar or corresponding manner as the implementation of Figures
56 to 60. More
particularly, the valve assembly is operable in a closed configuration (Figure
61), an open
configuration (Figure 62), a flow-restricted configuration (Figure 63) and a
screened
configuration (Figure 64). However, instead of the flow regulator 350, the top
sleeve is
provided with a check valve 360 installed within the annular region proximate
a top end of the
top sleeve for controlling the fluid flow along the annular region.
[200] It is appreciated that the implementations of Figures 27 to 64A provides
various
implementations of a valve assembly which includes a flow control device which
can be
isolated within an annular region and/or an annular chamber that can be
pressurized to
prevent cement from damaging the flow-controlling sleeve and its components
(e.g., the flow
control device, the latching mechanism 165, etc.). The annular region and the
annular
chamber can be pressurized via fluid flowing therein via interstices 135
defined between two
or more components of the valve assembly, or via vents 252 defined through the
top sleeve,
for example. Moreover, the flow control device of various implementations
enables reservoir
fluid to flow from the reservoir into the central passage. It is appreciated
that the production
flowpath does not necessarily include an annular flow area, which can reduce
the overall
production flowrates (e.g., when compared to the production flowrates through
the volume of
the central passage 106). Moreover, the described implementations can be
configured to
enable selectively switching between the various operational configurations.
In other words,
and for example, the valve assembly can be actuated between the open, closed
and/or
screened configurations, among others, as desired, and as described above.
[201] It should also be noted that the implementations of Figures 27 to 64A
can be run
downhole (e.g., installed within the wellbore) with the sleeve assembly (e.g.,
the top and
bottom sleeves) in a run-in position. The sleeves can be releasably secured to
the valve
housing in order to prevent accidental or undesired movement of the sleeves
prior to the valve
assemblies being in the desired location and/or configuration along the
wellbore. For example,
the sleeves can be pinned to the valve housing using shear pins, or via any
other suitable
fastening method or component which can be subsequently disengaged,
disconnected,
broken, etc.
[202] It should be appreciated from the present disclosure that the various
implementations
of the valve assembly and related components enable providing a cementable
valve assembly
48
Date Recue/Date Received 2022-09-28
with a dead-ended chamber for housing a flow control device. The valve
assembly can be
cemented down the wellbore along with the wellbore string it is integrated
with, where fluid
communication with the dead-ended chamber is not blocked, but restricted, such
that fluid
within the wellbore (e.g., water, brine, drilling mud, etc.) can flow therein
and pressurize the
dead-ended chamber. Therefore, subsequent fluids or materials being pumped
down the
wellbore string (e.g., cementitious material) are prevented from entering the
chamber. Once
cemented in place, the valve assembly can be operated in various operational
configurations,
including a flow-restricted configuration, where the dead-ended chamber is
integrated as part
of the fluid pathway for production fluid, and where the flow control device
is open to fluid flow
from the reservoir to control the production fluid flow. It is appreciated
that the flow control
device comes "pre-packaged" with the valve assembly (e.g., within the annular
region), and is
thus not required to be run downhole as part of a separate tubing string to
enable control of a
flow of production fluid.
[203] It should also be noted that, as previously mentioned, the annular
chamber is initially
pressurized via an ingress of wellbore fluids prior to cementing the wellbore
string. The fluid
which initially flows into the annular chamber can be residual fluid from
drilling out the wellbore
(e.g., brine, water, drilling mud, etc.). Therefore, it should be understood
that, if the well is
generally dry, an initial amount of fluid can be pumped downhole to pressurize
the chamber
(or be used as redundancy to make sure that the chamber is pressurized) before
pumping
cement downhole to secure the wellbore string. In some implementations, the
annular region
of the valve assembly can additionally be prepacked with fluid or a slurry
material, such as
grease, prior to running the valve assembly downhole. Having a prepacked
annular region can
help deter additional fluids from flowing therein. However, the annular region
remains in fluid
communication with the central passage such that initial wellbore fluid are
still allowed to flow
therein and pressurize the chamber, if need be, to prevent an inflow of cement
into the annular
region.
[204] The present disclosure may be embodied in other specific forms without
departing from
the subject matter of the claims. The described example implementations are to
be considered
in all respects as being only illustrative and not restrictive. For example,
in the implementations
described herein, the flow control device includes both the check valve and
the screen.
However, it is appreciated that an implementation of the valve assembly can
include only the
screen or only the check valve. In implementations including only the screen,
it is appreciated
that defining an annular flowpath is not required since the screened
production fluid can be
made to flow directly into the central passage of the valve assembly.
49
Date Recue/Date Received 2022-09-28
[205] In addition, in the above-described implementations, the annular region
and annular
chamber were defined about substantially the entire circumference of the top
sleeve (e.g., 360
degrees around the top sleeve). However, it should be understood that the
annular region and
corresponding annular chamber can be defined as one or more independent
section dispersed
around the top sleeve. In such implementations, the annular sections can
extend by any
suitable angle around the top sleeve, such as about 20, 30, 45, 60, 90 or 180
degrees, for
example. The annular region can alternatively be defined as multiple flow
channels, similar to
the through channels of the ring portion, where individual channels are
defined along generally
the entire length of the top sleeve, with each channel being provided with its
own flow control
device.
[206] Referring to Fig 65, in some implementations, the flow control device
can alternatively,
or additionally, include a flow restriction component 260 that can take the
form of a fluid
channel 262 that can be a tortuous path that winds (e.g., boustrophedonically)
across a portion
of the top sleeve (e.g., defined in an outer surface of the ring portion).
Shifting the top sleeve
can align the fluid channel with the housing port for enabling fluid
communication therewith.
Once the sleeve is mounted within a valve housing, the fluid channel 262 is
alignable with the
housing port. This sleeve facilitates providing variable flow restriction for
different valves using
the same component designs. It may be desirable to provide different valves
along a well with
different levels of flow restriction. In some implementations, a flow control
device, such as a
check valve device could be incorporated into the fluid channels.
[207] The present disclosure intends to cover and embrace all suitable changes
in
technology. The scope of the present disclosure is, therefore, described by
the appended
claims rather than by the foregoing description. The scope of the claims
should not be limited
by the implementations set forth in the examples, but should be given the
broadest
interpretation consistent with the description as a whole. Furthermore, in the
present
disclosure, an implementation is an example or embodiment of the valve
assembly and
surrounding components. The various appearances of "one implementation," "an
implementation" or "some implementations" do not necessarily all refer to the
same
implementations. Although various features may be described in the context of
a single
implementation, the features may also be provided separately or in any
suitable combination.
Conversely, although the valve assembly may be described herein in the context
of separate
implementations for clarity, it may also be implemented in a single
implementation. Reference
in the specification to "some implementations", "an implementation", "one
implementation", or
"other implementations", means that a particular feature, structure, or
characteristic described
Date Recue/Date Received 2022-09-28
in connection with the implementations is included in at least some
implementations, but not
necessarily in all implementations.
[208] As used herein, the terms "coupled", "coupling", "attached", "connected"
or variants
thereof as used herein can have several different meanings depending in the
context in which
these terms are used. For example, the terms coupled, coupling, connected or
attached can
have a mechanical connotation. For example, as used herein, the terms coupled,
coupling or
attached can indicate that two elements or devices are directly connected to
one another or
connected to one another through one or more intermediate elements or devices
via a
mechanical element depending on the particular context.
[209] In the above description, the same numerical references refer to similar
elements.
Furthermore, for the sake of simplicity and clarity, namely so as to not
unduly burden the
figures with several references numbers, not all figures contain references to
all the
components and features, and references to some components and features may be
found in
only one figure, and components and features of the present disclosure which
are illustrated
in other figures can be easily inferred therefrom. The implementations,
geometrical
configurations, materials mentioned and/or dimensions shown in the figures are
optional, and
are given for exemplification purposes only.
[210] In addition, although the optional configurations as illustrated in the
accompanying
drawings comprises various components and although the optional configurations
of the valve
assembly as shown may consist of certain geometrical configurations as
explained and
illustrated herein, not all of these components and geometries are essential
and thus should
not be taken in their restrictive sense, i.e. should not be taken as to limit
the scope of the
present disclosure. It is to be understood that other suitable components and
cooperations
thereinbetween, as well as other suitable geometrical configurations may be
used for the
implementation and use of the valve assembly, and corresponding parts, as
briefly explained
and as can be easily inferred herefrom, without departing from the scope of
the disclosure.
51
Date Recue/Date Received 2022-09-28
